ITU Rocket

ISTANBUL TECHNICAL UNIVERSITY  GRADUATE SCHOOL OF SCIENCE
ENGINEERING AND TECHNOLOGY
AEROSPIKE NOZZLE DESIGN AND ANALYSIS
M.Sc. THESIS
Sherif FARRAG
Department of Aeronautical and Astronautical Engineering
Aeronautical and Astronautical Engineering Graduate Programme
JUNE, 2020
ISTANBUL TECHNICAL UNIVERSITY  GRADUATE SCHOOL OF SCIENCE
ENGINEERING AND TECHNOLOGY
M.Sc. THESIS
Sherif FARRAG
511171132
Department of Aeronautical and Astronautical Engineering
Aeronautical and Astronautical Engineering Graduate Programme
Thesis Advisor: Prof. Dr. Fırat Oğuz EDİS
JUNE, 2020
ISTANBUL TEKNİK ÜNİVERSİTESİ  FEN BİLİMLERİ ENSTİTÜSÜ
AEROSPİKE NOZUL TASARIMI VE ANALİZİ
YÜKSEK LİSANS TEZİ
Sherif FARRAG
511171132
Uçak ve Uzay Mühendisliği Anabilim Dalı
Uçak ve Uzay Mühendisliği Yüksek Lisans Programı
Tez Danışmanı: Prof. Dr. Fırat Oğuz EDİS
HAZİRAN, 2020
Sherif Farrag, a M.Sc student of İTU Graduate School of Science Engineering and
Technology, student ID 511171132, successfully defended the thesis entitled
“AEROSPIKE NOZZLE DESIGN AND ANALYSIS”, which he prepared after
fulfilling the requirements specified in the associated legislations, before the jury
whose signatures are below.
Thesis Advisor: Prof. Dr. Fırat Oğuz Edis ..............................

İstanbul Technical University
Jury Members: Doç. Dr. Ayşe Gül Güngör .............................

Istanbul Technical University
Prof. Dr. Metin Muradoğlu ..............................

Koç University
Date of Submission : 14 June 2020

Date of Defense : 21 July 2020
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To my wife,
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FOREWORD
This thesis is considered to be as a development on the experience which I self-built

through the past few years. Especially, the highlight of my projects I built in 2015
which considered to be the most powerful student-built solid rocket engine in Turkey
that has been marked safe and launched by the ESRA and until the thesis written date.
I would like to thank the main reason that pushed me to overcome difficulties during
all phases of the project and without her I could not have reached this point. She is the
one who insisted to push me to choose the topic that I am interested in whatever other
considerations. However, designing and manufacturing rocket engine has put my life
in danger once in the past due to a serious rocket work accident, she has never let me
give up my passionate field! She is my wife Mrs. Hanaa Mostafa. I appreciate the
support, time and flexibility that my research advisor Prof. Dr. Fırat EDİS has offered
me during this master research and even my previous B.Cs. research. He has always
been a trustworthy mentor to me. Also, I appreciate the logistical support that Mr.
Ahmet Fathy has offered me during the analysis work of his research. Moreover, I
would like to thank Mr. Çağrı Eren Durkaya and Mr. Ibrahim Çiçek for the translation
effort they did.
June 2020 Sherif FARRAG

(R&D Engineer)
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TABLE OF CONTENTS
Page
FOREWORD ............................................................................................................. ix
TABLE OF CONTENTS .......................................................................................... xi
ABBREVIATIONS .................................................................................................. xv
SYMBOLS .............................................................................................................. xvii
LIST OF TABLES .................................................................................................. xix
LIST OF FIGURES ................................................................................................ xxi
SUMMARY ........................................................................................................... xxix
ÖZET……………………………………………………………………………xxxiii
1. INTRODUCTION .................................................................................................. 1
1.1 Nozzle Definition ............................................................................................... 1
1.2 Nozzle Types ...................................................................................................... 2
1.2.1 Conical nozzle ............................................................................................. 2
1.2.2 Bell nozzle................................................................................................... 3
1.2.3 Aerospike nozzle ......................................................................................... 3
2. LITERATURE SURVEY ...................................................................................... 5
2.1 Working Principle .............................................................................................. 5
2.2 Governing Equation ........................................................................................... 9
2.3 Detailed Angelino Method Discussion [2] [12] ............................................... 14
2.4 Thrust Calculations .......................................................................................... 16
2.4.1 Conical nozzle [4] [14] ............................................................................. 16
2.4.2 Aerospike nozzle [15] [16] [17] ................................................................ 17
2.5 Specific Impulse ............................................................................................... 19
3. NOZZLE CFD ANALYSIS & OPTIMIZATION ............................................ 21
3.1 Full Spike Nozzle ............................................................................................. 21
3.1.1 Cad model ................................................................................................. 21
3.1.2 Cfd mesh tool ............................................................................................ 22
3.1.2.1 Mesh setup ......................................................................................... 22
3.1.2.2 Mesh output........................................................................................ 23
3.1.3 Cfd fluent .................................................................................................. 24
3.1.4 Thrust calculations .................................................................................... 27
3.2 40% Truncated Aerospike Nozzle.................................................................... 28
3.2.1 Cad model ................................................................................................. 28
3.2.2 Cfd mesh tool ............................................................................................ 29
3.2.2.1 Mesh setup ......................................................................................... 29
3.2.2.2 Mesh output........................................................................................ 29
3.2.3 Cfd fluent .................................................................................................. 30
3.3 20% Truncated Aerospike Nozzle.................................................................... 32
3.3.1 Cad model ................................................................................................. 33
3.3.2 Cfd mesh tool ............................................................................................ 33
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3.3.2.1 Mesh setup.......................................................................................... 33
3.3.2.2 Mesh output ........................................................................................ 34
3.3.3 Cfd fluent................................................................................................... 35
3.4 40%Truncated - Blind Central Hole ................................................................. 37
3.4.1 Cad model ................................................................................................. 37
3.4.2 Cfd mesh tool ............................................................................................ 38
3.4.2.1 Mesh setup.......................................................................................... 38
3.4.2.2 Mesh output ........................................................................................ 38
3.4.3 Cfd fluent................................................................................................... 39
3.5 40%Truncated – 0.98%Flux Central Straight Bleed ........................................ 41
3.5.1 Cad model, mesh tool & boundary conditions .......................................... 43
3.5.2 CFD fluent ................................................................................................. 44
3.6 Hybrid Aerospike-Conical Nozzle-40%Truncated – 2.9%Flux Central Bleed.
................................................................................................................................ 46
3.6.1 Cad model ................................................................................................. 47
3.6.2 Cfd mesh tool ............................................................................................ 47
3.6.2.1 Mesh setup.......................................................................................... 47
3.6.2.2 Mesh output ........................................................................................ 49
3.6.3 Cfd fluent................................................................................................... 50
3.7 Hybrid Aerospike Conical Nozzle-40%Truncated – 5.9%Flux Central Bleed.52
3.7.1 Cad model ................................................................................................. 53
3.7.2 Cfd mesh tool ............................................................................................ 53
3.7.2.1 Mesh setup.......................................................................................... 53
3.7.2.2 Mesh output ........................................................................................ 55
3.7.3 Cfd fluent................................................................................................... 56
3.8 Nozzle Performance Summary ......................................................................... 59
4. STEERING CONTROL ...................................................................................... 61
4.1 90% Positioned Secondary Injection on 40% Truncated Aerospike Nozzle ... 65
4.1.1 Cad model ................................................................................................. 65
4.1.2 Cfd mesh tool ............................................................................................ 66
4.1.2.1 Mesh setup.......................................................................................... 66
4.1.2.2 Mesh output ........................................................................................ 69
4.1.3 Cfd fluent................................................................................................... 70
4.1.4 Side force calculations .............................................................................. 71
4.2 20% Positioned Secondary Injection on 40% Truncated Aerospike Nozzle
Design & Analysis .................................................................................................. 74
4.3 Secondary Jet Position Effect on Aerospike Nozzle Summary........................ 75
5. CONCLUSION .................................................................................................... 77
REFERENCES ......................................................................................................... 79
APPENDICES .......................................................................................................... 83
APPENDIX A ........................................................................................................ 83
APPENDIX B ......................................................................................................... 85
APPENDIX C ......................................................................................................... 92
APPENDIX D ........................................................................................................ 93
APPENDIX E ....................................................................................................... 100
xii
APPENDIX F ....................................................................................................... 102
APPENDIX G ...................................................................................................... 108
APPENDIX H ...................................................................................................... 110
APPENDIX I ........................................................................................................ 117
APPENDIX J........................................................................................................ 119
APPENDIX K ...................................................................................................... 122
APPENDIX L ....................................................................................................... 124
APPENDIX M...................................................................................................... 131
APPENDIX N ...................................................................................................... 133
APPENDIX O ...................................................................................................... 140
APPENDIX P ....................................................................................................... 142
APPENDIX Q ...................................................................................................... 155
APPENDIX R ...................................................................................................... 158
CURRICULUM VITAE ........................................................................................ 161
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ABBREVIATIONS
CAD : Computer Aided Drafting
CFD : Computational Fluid Dynamics
ITU : Istanbul Technical University
MOC : Method of Characteristics
OQ : Orthogonal Quality
SW : Solid Works
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SYMBOLS
A : Area
A* : Chocked Area
F : Force
Isp : Specific Impulse
K : Kelvin
L : Length
l : length of a characteristic segment
ℓ : Length of a characteristic segment
ṁ : Mass Flow Rate (Mass Flux)
M : Mach Number
M : Moment
P : Pressure
a : Atmospheric Pressure
c : Combustion Pressure
r : Radial Coordinates
R : Universal Gas Constant
T : Temperature
T : Thrust
v : Velocity
 : Mach Angle
 : Prandtl-Meyer angle
 : Geometric angle with the reference axis
 : Expansion Ratio
 : Heat Capacity Ratio
 : Correction Factor
 : Density
 : Derivation Angle
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 : Angle between thrust axis and vertical
Subscripts:
0 : Stagnation
“Base” or b : Aerospike Nozzle Front Base Section (if there is truncation)
e : Exit
t : Throat
thruster : Case Without Nozzle Centerbody
x : X Axis Direction
y : Y axis Direction
z : Z Axis Direction
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LIST OF TABLES
Page
Table 2. 1 : Conical nozzle. Divergence half angle relation with correction factor
[4]. ...................................................................................................................... 17
Table 3.1: Full spike nozzle face mesh setting......................................................... 23
Table 3.2: Full spike nozzle node & element mesh number. ................................... 24
Table 3.3: Full spike nozzle thrust Matlab code inputs. .......................................... 27
Table 3.4: Full spike nozzle thrust Matlab code outputs. ........................................ 27
Table 3.5 : 40% Truncated aerospike nozzle face & edge mesh settings. ................ 29
Table 3.6 : 40% Truncated aerospike element & node mesh number....................... 30
Table 3.7 : 40% Truncated aerospike nozzle Matlab thrust code inputs................... 31
Table 3.8 : 40% Truncated aerospike nozzle Matlab thrust code outputs................. 32
Table 3.9 : 20% Truncated aerospike nozzle face & edge mesh settings ................. 34
Table 3.10 : 20% Truncated aerospike nozzle node & element number................... 34
Table 3.11 : 20% Truncated aerospike nozzle Matlab thrust code inputs................. 36
Table 3.12 : 20% Truncated aerospike nozzle Matlab thrust code outputs............... 36
Table 3.13 : 40% Truncated – blind central hole aerospike nozzle face & edge mesh
settings. .............................................................................................................. 38
Table 3.14 : 40% Truncated – blind central hole aerospike nozzle node & element
number................................................................................................................ 39
Table 3.15 : 40% Truncated – blind central hole aerospike nozzle-Matlab thrust code
inputs. ................................................................................................................. 40
outputs. ............................................................................................................... 41
Table 3.17 : 40%truncated – 0.98%flux central straight bleed-Matlab thrust code
inputs. ................................................................................................................. 45
outputs. ............................................................................................................... 45
Table 3.19 : Hybrid aerospike conical nozzle- 40% truncated – 2.9% flux central
bleed- face & edge mesh setting. ....................................................................... 48
bleed- mesh element & node number................................................................. 49
bleed- Matlab thrust code inputs. ....................................................................... 51
bleed- Matlab thrust code outputs. ..................................................................... 51
bleed- mesh face & edge setting. ....................................................................... 54
bleed- element & node number. ......................................................................... 55
Table 3.25 : Hybrid aerospike conical nozzle-40%truncated – 5.9%flux central
bleed- Matlab thrust code inputs. ....................................................................... 57
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bleed- Matlab thrust code outputs. ..................................................................... 58
Table 3.27 : Nozzle Performance Summary. ............................................................ 60
Table 4.1 : 90% positioned Secondary Injection on 40% Truncated aerospike
Nozzle- body & face mesh setting. ............................................................................ 67
Table 4.2 : 40% Truncated aeropsike nozzle-90% secondary jet positioning- edge
mesh setting. ....................................................................................................... 69
Table 4. 3 : Mesh element & nodes number............................................................. 70
Table 4.4 : 20% secondary Jet position Performance outputs. ................................. 73
Table 4.5 : Secondary jet performance comparison for different configurations. .... 75
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LIST OF FIGURES
Page
Figure 1.1 : Typical temperature (T), pressure (p), and velocity (v) profiles in a de
Laval Nozzle [3]................................................................................................... 2
Figure 1.2 : Simplified diagrams of several different nozzle configurations and their
flow effects [4]. .................................................................................................... 2
Figure 1. 3 : Size comparison of bell and plug nozzle [from Berman and Crimp,
1961]. ................................................................................................................... 4
Figure 2.1 : How specific impulse changes with altitude for the Aerospike nozzle
and the Bell nozzle [5]. ................................................................................................ 5
Figure 2.2 : XRS=2200 linear aerospike engine test (Retrieved from NASA
Marshall Space Flight Center database). .............................................................. 6
Figure 2.3 : Model of aerospike with flow field [2].................................................... 7
Figure 2.4 : Exhaust Flow along a Truncated Aerospike Nozzle [2]. ......................... 7
Figure 2.5 : The four expansion regimes of a de Laval nozzle [3]: • under-expanded
• perfectly expanded • over-expanded • grossly over-expanded .......................... 8
Figure 2.6 : Exhaust Flow from a Full and Truncated Spike [2]. ............................... 9
Figure 2. 7 : Sketch of full-length aerospike nozzle contour according to Wang &
Qin study [6]. ..................................................................................................... 10
Figure 2.8 : The B-Spline Method [8]....................................................................... 11
Figure 2.9 : Two-dimensional plug nozzle [12]........................................................ 12
Figure 2.10 : Comparison of approximate and exact solutions in plug nozzle design
[12] where is b = r/re. ........................................................................................ 13
Figure 2.11 : Annular plug nozzle [12]. .................................................................... 14
Figure 2. 12 : Conical nozzle flow sketch [14]. ........................................................ 16
Figure 2.13 : Flow field characteristics of an aerospike nozzle [from Ruf and
McConnaughey, 1997]. ...................................................................................... 17
Figure 3.1 : Full spike nozzle 2D sketch................................................................... 22
Figure 3.2: Full spike nozzle mesh sectioning .......................................................... 23
Figure 3.3 : Full spike nozzle mesh map .................................................................. 23
Figure 3.4 : Full spike nozzle Mach contours using CFD ........................................ 25
Figure 3.5 : Full spike nozzle static pressure contours using CFD ........................... 26
Figure 3.6 : 40% truncated aeropsike nozzle 2D dimentional sketch ....................... 28
Figure 3.7 : 40% truncated aeropsike nozzle mesh sectioning ................................. 29
Figure 3.8 : 40% truncated aeropsike nozzle mesh map ........................................... 29
Figure 3.9 : 40% truncated aeropsike nozzle Mach contours ................................... 30
Figure 3.10: 40% truncated aeropsike nozzle static pressure contours..................... 31
Figure 3.11 : 20% truncated aeropsike nozzle 2D dimenstional sketch .................. 33
Figure 3.12 : 20% truncated aeropsike nozzle mesh sectioning ............................... 33
Figure 3.13 : 20% truncated aeropsike nozzle mesh map ......................................... 34
Figure 3. 14: 20% truncated aeropsike nozzle Mach contours ................................. 35
Figure 3.15 : 20% truncated aeropsike nozzle static pressure contours.................... 35
Figure 3.16 : 40% truncated-blind central hole aeropsike nozzle 2D dimenstional
sketch.................................................................................................................. 37
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Figure 3.17 : 40% truncated-blind central hole aeropsike nozzle mesh sectioning .. 38
Figure 3.18 : 40% truncated-blind central hole aeropsike nozzle mesh map............ 38
Figure 3.19 : 40% truncated-blind central hole aeropsike nozzle Mach contours .... 39
Figure 3.20 : 40% truncated-blind central hole aeropsike nozzle static pressure
contours .............................................................................................................. 40
Figure 3.21 : Turbine exhaust leaving the base for a truncated aerospike engine [18]
............................................................................................................................ 42
Figure 3.22 : Rocketdyne J-2T 250K Toroidal Aerospike [18] ................................ 42
Figure 3.23: 40%Truncated – 0.98%flux central straight bleed-Boundary conditions
definition ............................................................................................................ 43
Figure 3.24 : 40%Truncated – 0.98%flux central straight bleed-Mach contours ..... 44
Figure 3.25: 40%Truncated – 0.98%flux central straight bleed-static pressure
contours .............................................................................................................. 44
Figure 3.26 : Hybrid aeropsike conical nozzle-40%truncated – 2.9%flux central
bleed-2d dimensional sketch .............................................................................. 47
bleed- boundary conditions definition................................................................ 48
bleed- face & edge mesh setting ........................................................................ 48
bleed- mesh map................................................................................................. 49
bleed- Mach contours Figure…………………………………………………..50
Figure 3.31 : Hybrid aerospike conical nozzle-40%truncated – 2.9%flux central
bleed…........................................................................................................................50
bleed- 2D dimensional drawing ......................................................................... 53
bleed- boundary conditions definition................................................................ 54
bleed- mesh sectioning ....................................................................................... 54
bleed- mesh map................................................................................................. 55
bleed-Mach contours .......................................................................................... 56
bleed-static pressure contours ............................................................................ 56
Figure 4.1: Movable nozzle [20] ............................................................................... 62
Figure 4.2: Jet tabs on a rocket developed by Lockheed for the U. S. Air Force [20].
............................................................................................................................ 62
Figure 4.3 : Secondary injection [20] ........................................................................ 63
Figure 4.4 : Auxiliary "Vernier" thrusters [19] ......................................................... 63
Figure 4.5 : Aerodynamic control. Nike missile with fin stabilizers and canard
steering [20]........................................................................................................ 64
Figure 4.6 : 90% positioned Secondary Injection on 40% Truncated aerospike
Nozzle-2D dimnsional drawing ......................................................................... 65
Nozzle- control volume 2D dimensional sketch ................................................ 66
Nozzle- body & face mesh setting ..................................................................... 67
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Nozzle- detailed body & face mesh setting........................................................ 67
Nozzle- edge mesh setting ................................................................................. 68
Figure 4.11: 90% positioned Secondary Injection on 40% Truncated aerospike
Nozzle-detailed edge mesh setting ..................................................................... 68
Figure 4. 12 : 90% positioned Secondary Injection on 40% Truncated aerospike
Nozzle- mesh map .............................................................................................. 69
Nozzle- Mach contours ...................................................................................... 70
Nozzle- sectional Mach contours ar secondary jet center .................................. 70
Nozzle- pressure contours-ISO .......................................................................... 71
Nozzle- resultant side force map ........................................................................ 72
Figure 4.17 : 20% positioned secondary injection on 40% truncated aerospike
nozzle-2D dimensional sketch ........................................................................... 74
nozzle- static pressure contours-ISO .................................................................. 75
Figure B.1 : Full spike nozzle CAD model............................................................... 85
Figure B 2 : Full spike plug CAD model .................................................................. 85
Figure B.3 : Full spike nozzle boundary conditions definition ................................. 85
Figure B.4: Full spike nozzle element quality contours ........................................... 86
Figure B.5 : Full spike nozzle element quality chart ................................................ 86
Figure B.6: Full spike nozzle skewness Chart .......................................................... 86
Figure B.7: Full spike nozzle orthogonal quality chart ............................................. 87
Figure B.8: Full spike nozzle fluent convergence graph .......................................... 87
Figure B.9: Full spike nozzle velocity contours ....................................................... 87
Figure B.10: Full spike nozzle unfilled Mach lines .................................................. 88
Figure B.11 : Full spike nozzle streamlines .............................................................. 88
Figure B.12: Full spike nozzle temperature contours ............................................... 89
Figure B.13 : Full spike nozzle wall temperature with y axis .................................. 89
Figure B.14: Full spike nozzle wall adjacent static pressure with y axis ................. 90
Figure B.15 : Full spike nozzle wall Adjacent flow density with y axis .................. 90
Figure B.16: Full spike nozzle wall adjacent shear force with x axis....................... 91
Figure B.17 : Full spike nozzle throat exit velocity component in x direction ......... 91
Figure D.1: 40% Truncated aeropsike nozzle CAD model ...................................... 93
Figure D.2: 40% Truncated aeropsike plug CAD model .......................................... 93
Figure D.3: 40% Truncated aeropsike nozzle boundary condition definition .......... 94
Figure D.4: 40% Truncated aeropsike nozzle element quality contours .................. 94
Figure D.5: 40% Truncated aeropsike nozzle element quality chart ........................ 94
Figure D.6: 40% Truncated aeropsike nozzle skewness chart .................................. 95
Figure D.7: 40% Truncated aeropsike nozzle orthogonal quality chart ................... 95
Figure D.8: 40% Truncated aeropsike nozzle fluent convergence graph ................. 95
Figure D.9: 40% Truncated aeropsike nozzle velocity contours .............................. 96
Figure D.10: 40% Truncated aeropsike nozzle Mach lines ...................................... 96
Figure D.11: 40% Truncated aeropsike nozzle streamlines ...................................... 97
Figure D.12: 40% Truncated aeropsike nozzle temperature contours K .................. 97
Figure D.13: 40% Truncated aeropsike nozzle wall temperature with y axis .......... 98
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Figure D 14: 40% Truncated aeropsike nozzle wall adjacent static pressure with y
axis ..................................................................................................................... 98
Figure D.15: 40% truncated aeropsike nozzle wall shear stress with y position ...... 99
Figure F.1: 20% Truncated aeropsike nozzle CAD model ..................................... 102
Figure F. 2: 20% Truncated aeropsike plug CAD model ....................................... 102
Figure F. 3: 20% Truncated aeropsike nozzle boundary condition defenition ....... 102
Figure F.4: 20% Truncated aeropsike nozzle element quality contours ................. 103
Figure F.5: 20% Truncated aeropsike nozzle element quality chart ....................... 103
Figure F.6: 20% Truncated aeropsike nozzle skewness chart ................................ 103
Figure F.7: 20% Truncated aeropsike nozzle orthogonal quality chart .................. 104
Figure F.8: 20% Truncated aeropsike nozzle fluent convergence graph ................ 104
Figure F 9: 20% Truncated aeropsike nozzle velocity contours ............................. 104
Figure F.10: 20% Truncated aeropsike nozzle Mach lines ..................................... 105
Figure F.11: 20% Truncated aeropsike nozzle streamlines .................................... 105
Figure F.12: 20% Truncated aeropsike nozzle temperature contours ..................... 106
Figure F.13: 20% Truncated aeropsike nozzle wall temperature with y axis ......... 106
Figure F.14: 20% Truncated aeropsike nozzle wall adjacent static pressure with y
axis ................................................................................................................... 107
Figure F.15: 20% Truncated aeropsike nozzle wall shear stress with y position ... 107
Figure H.1: 40% Truncated aeropsike nozzle-blind central hole-nozzle CAD model
.............................................................................................................. 110
Figure H.2: 40% Truncated aeropsike nozzle-blind central hole-plug CAD model
.......................................................................................................................... 110
Figure H.3: 40% Truncated aeropsike nozzle-blind central hole-nozzle boundary
condition definition ......................................................................................... 111
Figure H.4: 40% Truncated aeropsike nozzle-blind central hole-nozzle element
quality contours ................................................................................................ 111
Figure H.5: 40% Truncated aeropsike nozzle-blind central hole-nozzle element
quality chart ...................................................................................................... 111
Figure H.6: 40% Truncated aeropsike nozzle-blind central hole-nozzle skewness
chart .................................................................................................................. 111
Figure H.7: 40% Truncated aeropsike nozzle-blind central hole-nozzle orthogonal
quality chart ...................................................................................................... 112
Figure H.8: 40% Truncated aeropsike nozzle-blind central hole-nozzle convergence
graph ................................................................................................................. 112
Figure H.9: 40% Truncated aeropsike nozzle-blind central hole-nozzle velocity
contours ............................................................................................................ 113
Figure H.10: 40% Truncated aeropsike nozzle-blind central hole-nozzle Mach lines
.......................................................................................................................... 113
Figure H.11: 40% Truncated aeropsike nozzle-blind central hole-nozzle streamlines
.......................................................................................................................... 114
Figure H.12: 40% Truncated aeropsike nozzle-blind central hole-nozzle temperature
contours ............................................................................................................ 114
Figure H.13: 40% Truncated aeropsike nozzle-blind central hole-nozzle wall
temperature with y axis .................................................................................... 115
Figure H.14: 40% Truncated aeropsike nozzle-blind central hole-nozzle wall
adjacent static pressure with y axis .................................................................. 115
Figure H.15: 40% Truncated aeropsike nozzle-blind central hole-nozzle wall shear
stress with x position ........................................................................................ 116
Figure J.1: 40%Truncated – 0.98%flux central straight bleed velocity contours ... 119
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Figure J.2: 40%Truncated – 0.98%flux central straight bleed streamlines ............ 119
Figure J.3: 40%Truncated – 0.98%flux central straight bleed temperature contours
.......................................................................................................................... 120
Figure J.4: 40%Truncated – 0.98%flux central straight bleed ............................... 120
Figure J.5: 40%Truncated – 0.98%flux central straight bleed base exit density with
y axis ................................................................................................................ 121
Figure J.6: 40%Truncated – 0.98%flux central straight bleed bleed exit velocity
with y axis ........................................................................................................ 121
Figure L.1: Hybrid aeropsike conical nozzle-40%truncated – 2.9%flux central
bleed-nozzle CAD model..................................................................... 124
bleed-plug CAD model .................................................................................... 124
bleed- element quality contours ....................................................................... 125
bleed-element quality chart .............................................................................. 125
bleed-skewness chart ........................................................................................ 125
bleed-orthogonal quality chart ......................................................................... 126
bleed-convergence graph ................................................................................. 126
bleed-velocity contours .................................................................................... 126
bleed-Mach lines .............................................................................................. 127
bleed-streamlines.............................................................................................. 127
Figure L 11: Hybrid aeropsike conical nozzle-40%truncated – 2.9%flux central
bleed-static pressure of base with y axis .......................................................... 128
bleed-Mach number of full exit section of the whole nozzle with y axis ........ 128
bleed-flow velocity component in x direction of full exit section of the whole
nozzle with y axis ............................................................................................. 129
bleed-wall shear stress with y position ............................................................ 129
Figure N.1: Hybrid Aeropsike Conical Nozzle-40%Truncated – 5.9%Flux Central
Bleed-nozzle CAD model .................................................................... 133
Bleed-plug CAD nozzle ................................................................................... 133
Figure N.3: Hybrid aeropsike conical nozzle-40%truncated – 5.9%flux central
bleed-element quality contours ........................................................................ 134
bleed-element quality chart .............................................................................. 134
bleed-skewness chart ........................................................................................ 134
bleed-orthogonal quality chart ......................................................................... 135
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bleed-convergence graph.................................................................................. 135
Bleed-velocity contours.................................................................................... 135
Bleed-Mach lines.............................................................................................. 136
Bleed-streamlines ............................................................................................. 136
Figure N.11: Hybrid Aeropsike conical nozzle-40%truncated – 5.9%flux central
bleed-temperature contours .............................................................................. 137
bleed-static pressure of base with y axis .......................................................... 137
bleed-Mach number of full exit section of the whole nozzle with y axis ........ 138
bleed-flow velocity component in x direction of full exit section of the whole
nozzle with y axis ............................................................................................. 138
bleed-wall shear stress with y position ............................................................. 139
Figure P.1: 90% positioned secondary injection on 40% truncated aerospike nozzle
CAD model .......................................................................................... 142
Figure P.2: 90% positioned secondary injection on 40% truncated aerospike nozzle-
mesh body partitioning ..................................................................................... 142
detailed body partitioning................................................................................. 143
detailed mesh elements1................................................................................... 143
detailed mesh element2 .................................................................................... 144
mesh quality contours....................................................................................... 144
detailed mesh quality contours1 ....................................................................... 145
Figure P.10: 90% positioned secondary injection on 40% truncated aerospike
nozzle- element quality chart ........................................................................... 146
nozzle- skewness chart ..................................................................................... 146
nozzle- orthogonal quality chart ....................................................................... 147
nozzle-convergence graph ................................................................................ 147
nozzle-wall Mach contours .............................................................................. 148
nozzle-Mach lines ............................................................................................ 148
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nozzle-velocity contours .................................................................................. 149
nozzle-detailed velocity contours ..................................................................... 149
nozzle-sectional velocity contours at secondary jet center .............................. 150
nozzle-secondary jet streamlines...................................................................... 150
nozzle-full streamlines ..................................................................................... 151
nozzle-full streamlines-ISO ............................................................................. 151
nozzle-pressure contours .................................................................................. 152
nozzle-detailed pressure contours .................................................................... 152
nozzle-sectional pressure contours at secondary jet center .............................. 153
nozzle-wall temperature contours .................................................................... 153
nozzle-temperature contours ............................................................................ 154
nozzle- sectional temperature contours at secondary jet center ....................... 154
Figure R.1: 20% positioned secondary injection on 40% truncated aerospike nozzle-
velocity contours. ................................................................................. 158
Mach lines ........................................................................................................ 158
detailed Mach lines. ......................................................................................... 159
pressure contours. ............................................................................................. 159
sectional pressure contours at secondary jet center.......................................... 160
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SUMMARY
This research is done mainly to design and optimize an annular aerospike nozzle
operating at sea level through four sections; First, to develop the equation of the
contour points. Second, optimize the nozzle by comparing the performance under
different configurations. Third, design of thrust vector control using secondary jets.
Fourth, presenting a new introduced concept in this research that has shown
increasing the thrust of 4.7%.
Engineers have introduced various of approaches to design an aerospike nozzle
contour. For example; Wang and Qin Study, The B-Spline Method, Rao Method,
Zebbiche and Youbi method, Foelsch approach and Angelino approximate
method. All these approaches are discussed in a detailed manner and finally
Angelino method is decided to be used to continue the research with due to the
accuracy it offered and simplicity. The method is based mainly on geometric
equation, expansion fan Prandtl-Meyer function and the isentropic flow relations.
Assuming that the nozzle operates on the ground (sea level) inside a wind tunnel.
Also, according to Angelino method the contour points are then determined using
a written Matlab code. Contour points are determined to give optimum
performance and optimum expansion using the right expansion ratio according to
the isentropic relations at atmospheric pressure (101325 Pa). The combustion
pressure and temperature are set to ~700 PSI and ~1500C. Since the nozzle is
axisymmetric around the nozzle main axis, a 2D Ansys analysis is performed. A
structured mesh is used and Ansys fluent is set to double precision to get high
accuracy while density-based solver is chosen to calculate the properties.
Sutherland law is set to control the fluid viscosity, ideal gas is assumed, second
order upwind flow and turbulent model of K-epsilon (2eqn) realizable is used.
Also, since nozzle is assumed to operate on sea level in a wind tunnel test, side
boundaries are set to wall since they are the wind tunnel wall. Also, as the nozzle
has an axis of symmetry. So, a 2-D analysis is applied on a half sectional planes
then using an axisymmetric property a complete result is obtained. Using these
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configurations aerospike nozzle is analyzed under various truncation percentages
(Full, 40%, 20%). It is found that truncation of 40% gives the optimum
performance since the expanded downstream flow has a very low pressure near or
little less than the atmosphere while truncation is creating a base area which adds
some thrust to the nozzle. Also, increasing the truncation to higher than 40%
decreases the performance since very important centerbody areas that have very
high flow pressure on have been removed. From thermal point of view 40%
truncation is better than full plug since the full spike tip has minimum wall mount
which will be affected dramatically from the exhaust high temperature. Also, using
a high truncation like 20% would result in high temperature zones in the base area
as observed from this research results.
For further optimizing on the 40% truncated nozzle, a blind hole is added at the
base center and then analyzed. Adding blind holes at the base center showed
increase in thrust and so the specific impulse since. Efforts have been done to
eliminate the vortices at the nozzle base zone. A used concept to reach that goal is
using some of the rocket exhaust itself. Most of liquid rocket engines have a turbine
to compress the fuel and oxidizer in a separate volume before injecting them into
the combustion chamber to meet the desired combustion pressure. In which is
called closed cycle rocket combustion or staged combustion cycle that has been
used in a considerable number of modern rockets, the turbine exhaust which uses
some of the fuel and oxidizer to run is injected in the combustion chamber to
increase to add to the thrust an amount. But here in our design the turbine exhaust
is injected through multi-mini nozzles located at the base to reduce the vortices
zone and add an amount to the thrust. The many small nozzles can be assumed as
a wide radial tube outlet with low pressure source (compared to the main
combustion chamber). Hence, a bleed is added to the central hole introduced
previously. A central bleed showed greater performance since the bleed gas
eliminate the vortices generation at the base. Also, it is noted that the base thrust
contribution to the whole thrust has increased. Till this point, 40% truncation with
central bleed has shown a great performance. It is fact that, injecting exhaust
through the base increases the thrust of the engine. However, the main
disadvantage is that the exhaust leaving the central bleed is not expanded any. So,
lots of energy would be lost as a thermal energy with the flow injected. This
research is proposing a new concept to solve that challenge in which called
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“Hybrid Aerospike-Conical Nozzle”. This new concept has been analyzed using
CFD and showed significant increase of thrust which is required and will result in
reduction in number of engines used in a particular rocket since a smaller number
of engines would produce the same amount of thrust. The idea of the Hybrid
Aerospike-Conical Nozzle is that it uses the unused nozzle central volume and
make a central bleed by opening the hole to the main combustion chamber and
reduces the loss by expanding the flow through convergent-divergent nozzle. This
concept can be summarized as a two merged nozzle inside each other. Aerospike
nozzle from outside and conical nozzle from inside. In this research a conical
nozzle with a 12° divergent angle is used to decrease loss of the unparalleled flow.
Also, the central flow is maximized by maximizing the throat area while keeping
the optimum expansion ratio to optimum between 700 PSI combustion pressure
and ambient pressure according to the isentropic relations. The Hybrid
Aerospike-Conical Nozzle is analyzed using CFD and the results showed a
significant thrust increase of 4.7%.
The last section of the research is discussing the thrust vector control of the
aerospike nozzle. In this research, a secondary injections method is used to thrust
vector control the nozzle due to the manufacturing simplicity since no moving
hydraulics, gimbals or moving actuator are required except for valves for each
injection nozzle. A ~1% mass flow rate of the primary flow flux is applied through
a 4.6mm inject nozzle placed on the contour and open to the main combustion
chamber pressure. It is found that the interaction between the side jet and primary
flow creates high pressure zone in front of the secondary jet and low-pressure zone
behind the secondary jet. Hence, Different inlet positions are applied on a 40%
truncated aerospike nozzle to optimize the best secondary nozzle position (20%
and 90% distances measured from the primary nozzle throat are applied and
compared). The 90% position showed clearly higher performance and side force
since the interaction between the primary flow and the secondary side jet creates a
stronger bow shock which increases the pressure in front of the secondary.
Moreover, positioning the nozzle near the tip minimized the low-pressure zone
since it is created between the secondary nozzle and the tip. Positioning the jet at
20% distance (measured from the throat) upstream increases the distance between
the secondary nozzle and the tip and so to the low-pressure zone. Hence, it is can
be concluded that positioning the secondary jet at 20% decreases the side force.
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AEROSPİKE NOZUL TASARIMI VE ANALİZİ
ÖZET
Bu araştırma temel olarak dairesel bir Aerospike lüle tasarlamak ve optimize etmek
için yapılmıştır ve dört bölümde incelenmiştir; İlk bölüm, kontur noktalarının denklem
geliştirilmesi. İkinci olarak, performansı farklı konfigürasyonlar altında karşılaştırarak
nozul optimizasyonu. Üçüncü olarak, ikincil jetler kullanılarak itme vektörü
kontrolünün tasarımı. Dördüncüsü, bu araştırmada % 4,7'lik itki artışı gösteren yeni
bir konsept sunumu.
Mühendisler, bir aerospike konturu tasarlamak için çeşitli yaklaşımlar geliştirdiler.
Örneğin; Wang ve Qin Çalışması, B-Spline Yöntemi, Rao Yöntemi, Zebbiche ve
Youbi yöntemi, Foelsch yaklaşımı ve Angelino yaklaşık yöntemi. Tüm bu yaklaşımlar
detaylı bir şekilde tartışılmış ve son olarak, sunduğu doğruluk ve kolaylık nedeniyle
Angelino yönteminin araştırmaya devam etmek için kullanılmasına karar verilmiştir.
Yöntem temel olarak geometrik denklem, genişleme fanı Prandtl-Meyer fonksiyonu
ve izantropik akış ilişkilerine dayanmaktadır. Nozülün bir rüzgar tüneli içinde yerde
(deniz seviyesinde) çalıştığı varsayıldı. Ayrıca, Angelino yöntemine göre, kontur
noktaları yazılı bir Matlab kodu kullanılarak belirlendi. Kontur noktaları, atmosferik
basınçta (101325 Pa) izantropik bağıntılara göre doğru genişleme oranı kullanılarak
optimum performans ve optimum genişleme sağlayacak şekilde belirlendi. Yanma
basıncı ve sıcaklığı ~ 700 PSI ve ~ 1500C'ye ayarlanmıştır. Nozul, nozül ana ekseni
etrafında eksenel simetrik olduğundan, bir 2D Ansys analizi gerçekleştirildi. Yapısal
bir mesh kullanılarak ve Ansys Fluent, yoğunluk tabanlı çözücüsü çift duyarlıkla
kullanıldı. Sutherland kanunu, akışkan viskozitesini kontrol etmek için ayarlanmış,
ideal gaz varsayılmış, ikinci derece rüzgar üstü ayrıklaştırma ve K-epsilon (2eqn)
gerçekleştirilebilir türbülanslı modeli kullanılmıştır. Ayrıca bir rüzgar tüneli testinde
nozülün deniz seviyesinde çalıştığı varsayıldığından, yan sınırlar rüzgar tüneli duvarı
olduklarından duvara ayarlanmıştır. Ayrıca, nozül bir simetri eksenine sahip
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olduğundan, yarım kesit düzlemlerine 2-D analiz uygulandıktan sonra eksenel simetrik
özellik kullanılarak tam bir sonuç elde edilir. Bunları kullanarak farklı nozul
konfigürasyonları, çeşitli kesme yüzdeleri altında analiz edilir (Tam, %40, %20).
Genişleyen akış atmosfere yakın ya da biraz daha düşük bir basınca sahipken, kesme,
nozüle biraz itme ekleyen bir taban alanı yarattığından %40'lık kesmenin optimum
performansı verdiği bulunmuştur. Ayrıca, kesme oranını %40'ın üzerine çıkarmak, çok
yüksek akış basıncına sahip çok önemli merkez alan alanları kaldırıldığı için
performansı düşürmektedir. Termal açıdan %40 kesme, tam tapadan daha iyidir, çünkü
tam spike uç, yüksek egzoz sıcaklığından önemli ölçüde etkilenecek olan minimum
duvar montajına sahiptir. Ayrıca, %20 gibi yüksek bir kesme kullanmak, bu araştırma
sonuçlarından gözlemlendiği gibi taban alanında yüksek sıcaklık bölgelerine neden
olur.
%40 kesilmiş nozulda daha fazla optimizasyon için, taban merkezine bir kör delik
eklendi ve ardından analiz yapıldı. Taban merkezine kör delikler eklemek, itme
kuvvetinde ve dolayısıyla özgül itkide artış göstemiştir. Nozul taban bölgesindeki
girdapları ortadan kaldırmak için efor sarfedildi. Bu hedefe ulaşmak için kullanılan bir
yöntem de roket egzozunun bir kısmını kullanmaktır. Sıvı roket motorlarının çoğu,
istenen yanma basıncını karşılamak için yanma odasına enjekte etmeden önce yakıtı
ve oksitleyiciyi ayrı bir hacimde sıkıştırmak için bir türbine sahiptir. Önemli sayıda
modern rokette kullanılan kapalı çevrimli roket yanması veya aşamalı yanma döngüsü
olarak adlandırılan, çalıştırmak için yakıt ve oksitleyicinin bir kısmını kullanan türbin
egzozu, itme kuvvetini artırmak için yanma odasına enjekte edilir. Ancak burada,
tasarımımızda türbin egzozu, girdap bölgesini azaltmak ve itme kuvvetini bir miktar
arttırmak için tabanda bulunan multi-mini nozullardan enjekte edilir. Birçok küçük
nozul, düşük basınç kaynaklı (ana yanma odasına kıyasla) geniş bir radyal boru çıkışı
olarak kabul edilebilir. Bu nedenle, daha önce girilen merkezi deliğe bir taşma payı
eklenir. Merkezi bir akış, tabandaki girdap oluşumunu ortadan kaldırdığından daha
yüksek performans gösterdi. Ayrıca, tüm itme kuvvetine taban katkısının arttığı da
belirtilmektedir. Bu noktaya kadar, merkezi akışla %40 kesinti kayda değer bir
performans gösterdi. Tabandan egzoz enjekte etmenin motorun itme gücünü artırdığı
bir gerçektir. Diğer yandan, ana dezavantaj, merkezi kanaldan çıkan egzozun herhangi
bir şekilde genişletilmemesidir. Dolayısıyla, enjekte edilen akışla termal enerji olarak
çok fazla enerji kaybedilecektir. Bu araştırma, "Hibrit Aerospike-Konik Nozul" adı
verilen bu sorunu çözmek için yeni bir konsept önermektedir. Bu yeni konsept, CFD
xxxiv
kullanılarak analiz edildi ve gerekli olan itme kuvvetinde önemli bir artış olduğunu
gösterdi. Böylece daha az sayıda motor aynı miktarda itme gücü üreteceğinden, belirli
bir rokette kullanılan motorların sayısında azalmaya neden olacak sonucu oratay
koyuyor. Hibrit aerospike-Konik Nozul fikri, kullanılmayan nozul merkezi hacmini
kullanması ve ana yanma odasına deliği açarak merkezi bir sızdırma yapması ve
yakınsak-ıraksak nozul aracılığıyla akışı genişleterek kaybı azaltmasıdır. Bu kavram,
dıştan aerospike ve içeriden konik nozul birleşimiyle iç içe iki birleştirilmiş nozul diye
özetlenebilir. Bu araştırmada, akış kaybını azaltmak için 12 derecelik farklı açıya sahip
bir konik nozül kullanılmıştır. Ayrıca, izantropik bağıntılara göre 700 PSI yanma
basıncı ve ortam basıncı arasında optimum genleşme oranını korurken boğaz alanını
maksimize ederek merkezi akış artırılır. Hibrit aerospike -Konik Nozul, CFD
kullanılarak analiz edildi ve sonuçlar, %4,7'lik önemli bir itme artışı gösterdi.
Çalışmanın son bölümünde, nozulun itme vektörü kontrolü incelenmiştir. Bu
araştırmada, her bir enjeksiyon nozulu için valfler dışında hareketli hidrolik, yalpa
çemberi veya hareketli aktüatör gerekmediğinden, itme vektörü nozulu kontrol etmek
için üretim kolaylığı nedeniyle ikincil bir enjeksiyon yöntemi kullanılmıştır. Birincil
akış akısının ~ %1 kütle akış hızı, kontur üzerine yerleştirilmiş ve ana yanma odası
basıncına açık 4.6 mm'lik bir enjeksiyon memesi yoluyla uygulanır. Yan jet ile birincil
akış arasındaki etkileşimin, ikincil jetin önünde yüksek basınç bölgesi ve ikincil jetin
arkasında düşük basınç bölgesi oluşturduğu bulunmuştur. Bu nedenle, en iyi ikincil
nozül konumunu optimize etmek için %40 kesilmiş bir aerospikeuna farklı giriş
konumları uygulanır (birincil nozul boğazından ölçülen %20 ve %90 mesafeler
uygulanır ve karşılaştırılır). Birincil akış ile ikincil yan jet arasındaki etkileşim, ikincil
önündeki basıncı artıran daha güçlü bir yay şoku yarattığı için, %90 pozisyon gösterdi
ki daha yüksek performans ve yan kuvvet elde edilir. Ayrıca, nozülün ucun yakınına
konumlandırılması, ikincil nozül ile uç arasında oluşturulduğu için düşük basınç
bölgesini en aza indirmiştir. Jeti % 20 mesafede (boğazdan ölçüldüğünde) yukarı
yönde konumlandırmak, ikincil nozül ile uç arasındaki ve dolayısıyla düşük basınç
bölgesine olan mesafeyi artırır. Bu nedenle, ikincil jeti %20'de konumlandırmanın yan
kuvveti azalttığı sonucuna varılabilir.
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1. INTRODUCTION
A rocket [1] is a flying vehicle that uses rocket engine to propel itself. The rocket
engine work by pushing exhaust formed from propellant carried on the rocket itself.
Rocket engines work by Newton’s third law which states that "every action has an
equal and opposite reaction" action and reaction and push rockets forward simply by
expelling their exhaust in the opposite direction at high speed, and can therefore work
in the vacuum of space. Various nozzle types are used direct a rocket exhaust flow.
The most used nozzles are Conical, Bell or Aerospike. Aerospike nozzles have been
introduced by the second half of the last century. However, it lakes to real test data and
deep design analysis at different conditions compared to the conventional conical and
bell shaped nozzle. Hence, this research aims to investigate the aerospike nozzle by
three ways. First, choosing the best approach to design an aerospike nuzzle contour by
comparing the result to the method of characteristics. Second, applying different
configurations to the nozzle and analyze it using CFD. Third, designing of thrust
control system using secondary jets and apply different configurations to optimize the
result. As aerospike nozzle is designed originally because it has features over the
conventional nozzles, this research is giving more investigation and optimization
configuration on aerospike nozzle to be used in design phases.
1.1 Nozzle Definition
A nozzle is a mechanical device [2] of varying cross section which controls the
direction and characteristics of the fluid flowing through it. They are used in rocket
engines to expand and accelerate the combustion gases, from burning propellants, so
that the exhaust gases exit the nozzle at supersonic or hypersonic velocities. The main
goal of a supersonic nozzle is to convert a maximum percentage of the thermal energy
of the flow to kinetic energy to achieve maximum performance. To do that most of
supersonic nozzles consists of two main sections; Convergent and divergent sections.
The flow sub sonically expands through the convergence section while increasing its
velocity till it reaches M=1 (Chocked condition) at the throat. Then it is continuing to
increase its velocity though the expansion divergent supersonic section till exhaust
leaves the nozzle with an ambient pressure in the best conditions. During this
convergent section thermodynamic parameters such as Pressure, Temperature and
Mach number vary as (Figure 1.1) shows.
1
Figure 1.1 : Typical temperature (T), pressure (p), and velocity (v) profiles in a de
Laval Nozzle [3].
1.2 Nozzle Types
Lots of nozzles types have been developed in history. They vary according to their
geometry but have the same working principle. Different nozzles have its own exhaust
treatment method and so its own performance and volume. For example, (Figure 1.2)
shows different Conical, Bell and aerospike nozzle having the same expansion ratio
but their volume occupied changes dramatically from one to another. In this section
three types of nozzles (conical, bell and aerospike) are being discussed due to its
relation to this research.
Figure 1.2 : Simplified diagrams of several different nozzle configurations and their
flow effects [4].
1.2.1 Conical nozzle
Conical nozzle is similar to all nozzle types. It has convergence-divergence sections.

The convergence angle usually is set to 45°. But, its divergent section differs from the
others that it diverges at a constant angle (usually 12°-15°) giving it a simple conical
shape. Due to that simplicity most early rocket engines used this type. On the other
hand, the flow leaves the conical nozzle with the same angle that the divergence section
has. So, it suffers from high losses since the flow is not parallel to the rocket axis.
2
Engineers minimized these losses by decreasing the divergent angle. But, again
decreasing the divergent angle resulted in a very long nozzle-specially at high
altitudes-which adds more weight to the overall nozzle mass which is not required.
Other disadvantages are the manufacturing difficulties and the over stress loads.
1.2.2 Bell nozzle
The de Laval nozzle (or Bell Nozzle) [3] was originally developed in the 19th century
by Gustaf de Laval for use in steam turbines. It was first used in an early rocket engine
developed by Robert Goddard, one of the fathers of modern rocketry. It has since been
used in almost all rocket engines, including Walter Thiel's implementation, which
made possible Germany's V-2 rocket. Since the Bell nozzle consists of external bell-
shaped contour, it can reach higher expansion ratios faster than the conical nozzle and
then achieve shorter length. As the combustion gas enters the rocket nozzle, it is
traveling at subsonic velocities. As the throat constricts, the gas is forced to accelerate
until at the nozzle throat, where the cross-sectional area is the least, the linear velocity
becomes sonic. From the throat the cross-sectional area then increases, the gas expands
and the linear velocity becomes progressively more supersonic. The linear velocity of
the exiting exhaust gases can be calculated using the following equation:
TR 2ϒ 𝑃 ϒ−1
ve =√ 𝑀 [1 − ( 𝑝𝑒) ϒ ] (1.1)
ϒ−1
1.2.3 Aerospike nozzle

The aerospike (or plug) nozzle concept that has been under development since the
1950s [2] is yet to be utilized on a launch platform. The aerospike nozzle delivers
better performance compared to present day bell nozzle. The aerospike nozzle is a bell
nozzle with its nozzle profile turned inside out. Flow of combustion gases is directed
radially inward towards the nozzle axis. This concept is the opposite of a bell nozzle
which expands the flow away from the axis along diverging nozzle walls.
Unlike aerospike nozzle in a standard bell nozzle, flow expansion continues regardless
of what the ambient pressure is. and the flow can continue to over-expand until it
separates from the nozzle walls. But, aerospike nozzle has a compensation feature that
the flow always attached to the nozzle wall while expands till it reaches ambient
3
pressure as there is no outside wall to control it. Another important advantage of an
aerospike nozzle that it is small compared to a bell and conical nozzle has the same
expansion ratio as shown in Figure 1.2 & Figure 1.3. Also, aerospike nozzle has higher
performance than a bell or conical nozzle having the same expansion ratio as shown
in Figure 2.1.
Figure 1. 3 : Size comparison of bell and plug nozzle [from Berman and Crimp,
1961].
Another advantage of the aerospike engine that it uses a simple gas generator cycle
with a lower chamber pressure than typical rocket engines reducing the risk of a
catastrophic explosion. Although low chamber pressures result in reduced
performance, the aerospike's high expansion ratio availability makes up for this
deficiency.
Aerospike nozzles also are like bell nozzles can be directed and controlled using
secondary jets as discussed lately in this research which replaces the huge mechanical
moving gambles to rotate the whole nozzle.
4
2. LITERATURE SURVEY
An aerospike nozzle has a spike in the center (And that how is gained its name) of the
nozzle. Aerospike nozzle can be described as an inverted bell nozzle where the flow
expands on the outside of the nozzle instead of being completely constrained by the
nozzle walls. Features of the aerospike nozzle has attracted the researchers to give
deeper studies about it since mid-1950s through the 1960s.
2.1 Working Principle
The term “aerospike” derives from the fact that the central spike need not be a real,
solid surface; the spike can be aerodynamically formed by injecting gases from the
engine base. The nozzle exhaust flow is free to expand through a series of expansion
fans centered at the lip (Figure 2.3) on the open sides and self-adjust to static pressure
changes with altitude. As shown in Figure 2.1, this automatic altitude compensation
of the exhaust gases allows the nozzle to run at more optimum conditions and higher
specific impulse than a conventional fixed-geometry, bell-type nozzle, which is
designed to be optimum for only one altitude.
Figure 2.1 : How specific impulse changes with altitude for the Aerospike nozzle
and the Bell nozzle [5].
Aerospike nozzle can be classified according to two important features, truncation and
geometric shape. It can be designed to have full spike(plug) which gives maximum
specific impulse for the given inputs. Or truncated with various truncations
percentages. Truncation usually produces vortices at the base area (Figure 2.4) which
is treated with central bleed to overcome that thrust loss. Also, they can be classified
according to geometry as it can be linear or annular. The linear aerospike nozzle has a
5
linear pattern of mini expansion nozzles that direct the flow perpendicular to the spike
surface on both sides equally. And thrust vectoring can be controlled through
controlling the amount of mass flow rate coming from each nozzle. The second
aerospike type which is chosen to be studied in this research is the annular aerospike
nozzle. An annular aerospike nozzle has higher efficiency and higher specific impulse
than linear aerospike nozzle since the nature of the linear nozzle produces turbulence
similar to wingtip vortices as shown in Figure 2.2.
Figure 2.2 : XRS=2200 linear aerospike engine test (Retrieved from NASA Marshall
Space Flight Center database).
On the other hand, a linear aerospike nozzle length can be lengthened in order to
produce more thrust and can be fitted easily in a space craft. Also, the fact that is
consists of mini thrusters causes less instabilities probabilities. Over all in this research
we chose to work with the annular aerospike nozzle as it has higher efficiency, impulse
and has a closer combustion features to a bell nozzle. The main advantage to the
annular aerospike nozzle design (both full length and truncated spike) is its altitude
compensation ability below or at its design altitude. More specifically, the aerospike
will not suffer from the same overexpansion losses a bell nozzle suffers and can
operate near optimally, giving the highest possible performance at every altitude up to
its design altitude.
6
Figure 2.3 : Model of aerospike with flow field [2].
Figure 2.4 : Exhaust Flow along a Truncated Aerospike Nozzle [2].
However, aerospike nozzle can suffer from over expansion or under expansion (Figure
2.6) like a conventional bell nozzle (Figure 2.5). In a bell nozzle an under expansion
happens when the nozzle operates at higher altitude than the design one. So, the flow
exits the nozzle at higher pressure than the atmosphere. On the other hand, it suffers
overexpansion when operates on lower altitudes than the designed one so the flow
exits at lower pressure than the altitude faces compression from the ambient medium.
7
Figure 2.5 : The four expansion regimes of a de Laval nozzle [3]:
• under-expanded
• perfectly expanded
• over-expanded
• grossly over-expanded
In an aerospike nozzle the flow compensates automatically to the ambient pressure

reduces the thrust losses however it still suffers from over expansion and under
expansion when operating on different altitude from the designed one. However, these
losses are minimal as the outer surface of the nozzle is virtual consists of the
atmosphere itself enabling the flow to expand comfortably. So, in another way the
expansion ratio of an aerospike nozzle is determined from the ambient pressure not the
nozzle geometry. In fact, to be able to compare an aerospike nozzle to a bell nozzle
overexpansion and under expansion should be judged separately. A CFD analysis
shows that an over expanded aerospike nozzle is a way better than an over expanded
bell nozzle having the same expansion ratio. On the other hand, an under expanded
bell nozzle is better than an under expanded aerospike nozzle having the same
expansion ratio and again working on the same altitude. That is because an over
expanded bell nozzle produces vortices at the nozzle tips which causes losses and an
under expanded aerospike nozzle produces reflected shock waves at the lip causes gain
losses. So, it is recommended to design the aerospike nozzle with a higher expansion
ratio as much as possible in order to gain maximum performance. Overall if we did
that, we got a better performance and lighter nozzle than a bell nozzle designed for the
same application and altitude. Taking in mind that the nature of the aerospike nozzle
enables us to make a very high expansion ratio nozzle it can saves 25%-35% more fuel
than conventional nozzles at lower altitudes and 5%-6% at higher altitude due to the
fact that it can achieve higher expansion ratios.
8
Figure 2.6 : Exhaust Flow from a Full and Truncated Spike [2].
2.2 Governing Equation
Determining the Contour of an aerospike nozzle plug plays a vital and most important
point of designing. Although it controlled by the same physics, various approaches
have been developed to determine the spike contour.
A. Wang and Qin Study [6]. which assumed the primary nozzle contour to
be approximated by two circular arcs and a parabola; the plug contour
is approximated by a parabola and a third-order polynomial (Figure
2.7). This method is mainly built on the assumption that the exhaust
deviation angle from primary nozzle axis after expansion wave ED is
half of that after expansion wave EF under design condition. Passing
EF, the exhaust pressure becomes equal to the ambient pressure at
design altitude. for mass conservation, the length L of EF can be
determined by the density r, velocity v and Mach number M of exhaust
behind the expansion wave EF with L = ṁM/ rvW, W is the width of
the plug. Then, combined with the inclination of EF, coordinates of F
can be obtained. As it is assumed that the turning angle of exhaust
passing expansion wave ED is /2 and flow parameters along ED are
achieved by Prandtl–Meyer function with the same way applied to EF,
thus, the position of point D is also determined. Not only three critical
points C, D and F are fixed but also tangent angles at points C and F
are known, combined with connecting condition at point D, coefficients
9
in parabola CD and the third-order curve DF are solved. After that the
Parabolas BC, CD and the Cubic polynomial curve DF equations
coefficients can be determined.
Figure 2. 7 : Sketch of full-length aerospike nozzle contour according to Wang &

Qin study [6].
This method is an approximated method and does not show a great

accuracy with respect to the flow characteristics at each point of the
contour.
B. The B-Spline Method [7] [8]

In this method B-Spline method is used to generate various random
curves using these equations then test each individually using CFD
analysis.
𝑛+1
𝑥(𝑢) = ∑𝑖=1 𝑋𝑖 𝑁𝑖,𝑘 (𝑢)
{ 𝑛+1 𝑛 ≥𝑘−1 (2.1)
𝑦(𝑢) = ∑𝑖=1 𝑌𝑖 𝑁𝑖,𝑘 (𝑢)
𝑢−𝑢𝑖 𝑢𝑖+𝑘 −𝑢
𝑁𝑖,𝑘 (𝑢) = 𝑢 𝑁𝑖,𝑘−1 (𝑢) + 𝑢 𝑁𝑖+1,𝑘−1 (𝑢) (2.2)
𝑖+𝑘−1 −𝑢𝑖 𝑖+𝑘 −𝑢𝑖+1
1, 𝑢𝑖 < 𝑢 < 𝑢𝑖+1

𝑁𝑖,1 (𝑢) = { (2.3)
0, 𝑜𝑡ℎ𝑒𝑟𝑤𝑖𝑠𝑒
10
Figure 2.8 : The B-Spline Method [8].
C. Rao Method [9]

In this method, the maximum thrust is obtained by nozzle contour
according to fixed length of the nozzle and constant ambient pressure.
The assumptions of the study are non-viscous and isentropic flow
expansion. In this study, the variational integral is formulated along
with control surface in output of nozzle and the characteristic of flow
is determined in the control surface and the nozzle contour is
constructed by the method of characteristics to meet desired flow. The
major problem with this approach is assuming a constant length of the
nozzle, assuming a constant characteristic slope contour and the
complexity of the design process.
D. Zebbiche and Youbi [10], investigate a method based on the use of the
Prandtl-Meyer function of a perfect gas to design the contour of a plug
nozzle of arbitrary shape and specified exit flow conditions. Using this
method, the condition of designed nozzles in supersonic flow was
compared with common bell-shaped nozzle that the results indicate of
optimization of plug nozzle in term of thrust generation. This method
is very promising but suffer from complexity.
11
E. Another approach of designing an aerospike nozzle contour can be
found such as Foelsch method [11]. It is known that the equations for
the nozzle's contours are derived by integration of the characteristic
equations of the axially symmetric flow. Since it is not possible to
integrate these equations mathematically in an exact form, it was
necessary to find a way to approximate the calculations. In this method
the approximation offers itself by considering and comparing the
conditions of the flow in a cone with those in a nozzle, as a linearization
of the characteristic equations.
F. Angelino approximate method [12]

This method is used for axisymmetric plug nozzles derived from a
simple exact technique valid in the two-dimensional case. The method
mainly uses Prandtl-Meyer function and the isentropic relations applied
to a series of expansion fans start at the lip A (Figure 2.9). This method
is a way simpler than the exact method of characteristics method shown
in [13].
Figure 2.9 : Two-dimensional plug nozzle [12].
12
Figure 2.10 : Comparison of approximate and exact solutions in plug nozzle design
[12] where is b = r/re.
As seen from (Figure 2.10) the Angelino Approximate Method is almost identical to
the exact solution. Hence, Angelino is chosen due to is simplicity and accuracy relative
to the exact MOC exact solution.
13
2.3 Detailed Angelino Method Discussion [2] [12]
Figure 2.11 : Annular plug nozzle [12].
Assumptions and boundaries:
The derivation starts with assuming a chocked nozzle which means it reached the
maximum mass flow rate and the flow is sonic at the throat AB (Figure 2.11). So that,
Pe/Pt > 0.528 for  Also flow is assumed to expand according to Prandtl-Meyer
function through a centered wave originating at the plug nozzle lip. The streamline
passing through point B is the required contour profile. And it is assumed that the line
between the lip A and any point on the contour is a characteristic line which has
constant properties. For maximum performance it is assumed the flow exits the nozzle
parallel to the nozzle axis to have the maximum thrust component in the rocket axis.
Also, the flow is assumed to be parallel to nozzle contour at any point adjacent to the
wall. Angelino method ideal inviscid flow and isentropic process so all isentropic
relations are applicable.
Contour Determination:
It is known from Prandtl-Meyer theory that:
1
sin-1(𝑀) (2.4)
ϒ+1 ϒ−1
 √ϒ−1 tan−1 (√(ϒ+1) (𝑀2 − 1)) − tan−1 √𝑀2 − 1 (2.5)
From the geometry of (Figure 2.11) it can be concluded equation (2.6), (2.7), (2.8) &
(2.9):
e -  (2.6)
14
𝑟𝑒−[𝑟𝑒 2 −(AM sin α/π)]1/2
ℓ= , X = ℓ cos Y= ℓ sin  (2.7)
sin α
Ae = π(𝑟𝑒2 − 𝑟𝑏2 ) (2.8)

π(𝑟𝑒2 −𝑟𝑏2 )
At = (2.9)
𝑐𝑜𝑠𝑣𝑒
It is known that: 
Ae / At (2.10)
From Isentropic flow Mach number relations equation (2.11) & (2.12) are retrieved:
−ϒ
𝑃 ϒ−1
= (1 + 𝑀2 )ϒ−1 (2.11)
𝑃𝑡 2
ϒ+1
ϒ+1 ϒ−1 2 2(ϒ−1)
ϒ+1−2(ϒ−1) (1+ 2 𝑀 )
 
2 𝑀
Equations in (2.7) presents the required contour of the spike nozzle. Matlab code in
APPENDIX A determines this contour equations of a full spike nozzle with the
following inputs (rb = 0 as it is full nozzle, rt = 0.05mm, Pt = 700 PSI, Patm = 101325
Pascal, ϒ = 1.4.)
First, the exit Mach number Me for optimum condition as Pe=Patm is calculated from
equation (2.11). Prandtl-Meyer angle for the last expansion fan  at exit is calculated
from equation (2.5). The optimum expansion ratio is calculated from equation (2.12).
Then by dividing equation (2.8) by equation (2.9) and by knowing the value of re is
determined. Ae & At now can be calculated from equation (2.8) & equation (2.9)
respectively. is determined for Me from equation (2.4). Now the position of the last
point of the contour can be calculated from equations (2.7) since all unknowns are
determined. In order to calculated the rest of the contour points a vector is created that
contains Mach numbers between M=1 at throat and M=Me at the exit with step of
0.001. for each Mach number A, ence, ℓ, X & Y are calculated like previously
described for Me. The resultant vectors X, Y present the contour curve (Figure 1.12).
15
Figure 2.12: Full spike plug contour generated using Angelino method using
APPENDIX A Matlab code.
2.4 Thrust Calculations

2.4.1 Conical nozzle [4] [14]
Figure 2. 12 : Conical nozzle flow sketch [14].

Momentum Equation applied to conical nozzle Figure (1.13):
∑ 𝐹𝑥 = 𝑇 + (𝑝𝑎 − 𝑝𝑒 )𝐴𝑒 ∫𝐶𝑆 𝜌(𝑣⃗. 𝑛⃗⃗)𝑣𝑥 𝑑𝐴 (2.13)

Ideal Nozzle Thrust:
𝑇𝑖𝑠𝑒𝑛𝑡𝑟,1−𝑑 = 𝑚̇𝑣𝑒 + (𝑝𝑒 − 𝑝𝑎 )𝐴𝑒 (2.14)
Real nozzle thrust due to convergent angle loss:
1+cos 𝛼
𝑇𝑐𝑜𝑛𝑖𝑐 = [𝑚̇𝑣𝑒 + (𝑝𝑒 − 𝑝𝑎 )𝐴𝑠𝑝ℎ ] (2.15)
2
16
1
2 (1 + cos 𝛼)(2.16)
As discussed in section (1.2.1) the divergent angle is proportional to the losses and so
inversely proportional to the correction factor as shown in Table 2.2.
Table 2. 1 : Conical nozzle. Divergence half angle relation with correction factor
[4].
Nozzle Cone Divergence Half Angle, α (deg) Correction Factor, 
0 1.0000
2 0.9997
4 0.9988
6 0.9972
8 0.9951
10 0.9924
12 0.9890
14 0.9851
15 0.9830
16 0.9806
18 0.9755
20 0.9698
22 0.9636
24 0.9567
2.4.2 Aerospike nozzle [15] [16] [17]
Figure 2.13 : Flow field characteristics of an aerospike nozzle [from Ruf and
McConnaughey, 1997].
T = Fthruster + FCenterbody + Fbase (2.17)
17
An aerospike nozzle produces three components of thrust equation (2.17):
1- Thrust generated from the exhaust momentum leaving the combustion chamber
throat (Thruster) at high pressure equation (2.18).
2- Thrust generated from exhaust pressure acting towards the center body contour
surface equation (2.19).
3- Extra Thrust generated due to high pressure region due to vortices shown in
(Figure 2.14) at the nozzle base (if exists) equation (2.20)
Fthruster = (ṁvexit + (pexit-p0)Aexit)cos θ (2.18)
Fthruster = thrust force acting on the thrust

𝑚̇ = mass flow rate
vexit = exhaust gas velocity at the nozzle exit
pexit = pressure of the exhaust gases at the nozzle exit
Aexit = cross-sectional area of the nozzle exit
θ = angle between the thrust axis and the vertical
Fcenterbody = ∫ Acenterbody (pcenterbody − p∞ )𝑑A (2.19)

Fcenterbody = thrust force acting on the centerbody
Acenterbody = cross-sectional area of the centerbody moving along the nozzle axis
Pcenterbody = pressure of the exhaust gases on the centerbody moving along the nozzle
axis
p∞ = ambient pressure of the atmosphere
Fbase = (pbase – p∞ ) Abase (2.20)
Fbase = thrust force acting on the base

Pbase = pressure of the re-circulating flow on the base
p∞ = ambient pressure of the atmosphere
Abase = cross-sectional area of the base
18
2.5 Specific Impulse
Specific impulse is the change in momentum per unit mass for rocket fuels, or rather
how much more push accumulates as you use that fuel. This number represents a key
value when designing a rocket engine and its nozzle.
Thrust
Isp = Rate of propellant usage (2.21)
19
20
3. NOZZLE CFD ANALYSIS & OPTIMIZATION
In this section Aerospike nozzle is analyzed, studied and compared according to

different configurations and fixed environmental conditions as following:
1- Full Spike Nozzle

2- 40% Truncated Aerospike Nozzle
3- 20% Truncated Aerospike Nozzle
4- 40%Truncated - Blind Central Bleed
5- 40%Truncated – 0.98%Flux Central Straight Bleed
Then a new concept is first introduced in this research through the
following:
6- Hybrid Aerospike-Conical Nozzel-40%Truncated – 2.9%Flux Central
Bleed
7- Hybrid Aerospike-Conical Nozzel-40%Truncated – 5.9% Max Flux
Central Bleed with full convergent divergent conical nozzle.
3.1 Full Spike Nozzle
In this section Full aerospike nozzle is designed and analyzed using CFD, Total thrust,
Specific impulse calculated using Matlab using CFD output data. Plug 3D Model is
generated using SolidWorks to calculate the nozzle mass.
3.1.1 Cad model
From Angelino method used in the Matlab code, the full aerospike nozzle is drawn
(Figure 3.1)
21
Figure 3.1 : Full spike nozzle 2D sketch.
Besides thrust as a key factor of design criteria, mass is important too as it affect
directly the thrust to weight ratio of a rocket. In order to keep tracking of the mass of
the nozzle and be able to compare their masses at different configurations, material is
chosen to be plain carbon steel due to its high strength and temperature withstanding
properties.
Using SolidWorks evaluation tool for just the plug part (Figure B.2) using steel density
of 0.01 g/mm3 results in mass of 1582.87 g for current volume of 202941.44 mm3.
3.1.2 Cfd mesh tool
3.1.2.1 Mesh setup
Table 3.1: General mesh settings.

Use Advanced Size Function On: Proximity and Curvature
Relevance Center, Span Angle Center Fine
Smoothing High
Max Face size, Max size 2mm
Growth rate 1.2
22
Figure 3.2: Full spike nozzle mesh sectioning.
As shown in (Figure 3.2) a control surface is prepared and divided into three regions
(A, B & C) in order to have the ability to decrease the element size in regions near the
contour and increase is in far regions to save processing time while maintaining
reasonable accuracy for the case to converge. As seen in (Table 3.1) this strategy is
applied while setting the behavior to hard as it will give priority to element mesh size
on the entity unlike the soft behavior as when is used the size control may be affected
by proximity, curvature and local re-meshing.
Table 3.1: Full spike nozzle face mesh setting.

Section Element size Behavior
Face A 1mm Hard
Face B 0.5mm Hard
Edges C (Contour, Lip, Combustion 0.1mm Hard
Chamber)
3.1.2.2 Mesh output
Figure 3.3 : Full spike nozzle mesh map.
23
As a result of the mesh strategy a control surface (Figure 3.3) is obtained with high
element density near the contour. It can be seen from (Figures B.4-7) most of the
elements shown in (Table 3.2) has quality and orthogonal quality near the one while
maintaining most of the elements’ skewness near zero which indicates a high mesh
overall quality as seen in (Figures B.4-7).
Table 3.2: Full spike nozzle node & element mesh number.
Nodes 100007
Elements 98369
3.1.3 Cfd fluent

The choose of fluent solver setting play a vital role in the final CFD solution. Hence,
solver settings have been chosen to meet the current axisymmetric compressible
supersonic flow as seen in (Table 3.2).
Table 3.2 : Fluent settings.

Property Setting
Precision Double Precision
Solver Type Density-Based (More accurate for compressible flow)
Time Steady
2D Space Axisymmetric
Energy On
Viscous Model k-epsilon (2eqn) Realizable
Material Air
Density Ideal Gas
Viscosity Sutherland
Boundary Pressure Input: 4800000 Pascal
Conditions Pressure Input Initialization 4700000 Pascal
Inlet Total Temperature: 1773k
Pressure Outlet: 101325 Pascal
Outlet Total Temperature: 300k
Far field: Is set to Wall as it is assumed to be tested in a wind tunnel
24
Table 3.3 (continued) : Fluent settings.
Solution Method Formulation:
Implicit
Flux Type:
Roe-FDS
Gradient:
Least squares Cell Based
Flow:
Second Order Upwind
Turbulent Kinetic Energy:
Second Order Upwind
Turbulent Dissipation rate:
Second Order Upwind
Solution Initialization From Pressure Input
Number of Iterations Depends on the nozzle but
generally >5000
Figure 3.4 : Full spike nozzle Mach contours using CFD.
25
Figure 3.5 : Full spike nozzle static pressure contours using CFD.
As seen from streamlines and Mach lines of Figures B.10,11 & Figure 3.4 the flow
leaves the lip of the nozzle almost straight parallel to the nozzle axis which indicates
an optimum flow expansion at the given ambient conditions and that was expected
since the Matlab code in APPENDIX A designed an aerospike contour at ambient
pressure. Also, another indication of high performance can be concluded by studying
(Figure 2.6); The Figure shows a three expansion cases of aerospike nozzle (optimum,
over expanded and under expanded). It can be concluded from the Figure an over
expanded aerospike nozzle creates a Mach diamonds due to the shock waves created
from the reflected Mach waves from the contour and from the wave on the other side
of the nozzle. Also, an under expanded aerospike nozzle shows a shock waves due to
the expanded flow interaction with the surrounding ambient air. So, since we cannot
see shockwaves (Mach diamonds or near the shear layer between the exhaust and the
ambient). Hence, the flow is optimum expanded as designed. It can be shown that in
(Figure 3.5) the flow starts to expand gradually from the lip to near ambient at the
contour tip as expected. Fluent numerical values are listed in (Table 3.3) to be used in
Matlab thrust code in the next section.
26
Table 3.3: Full spike nozzle thrust Matlab code inputs.
Throat average Exit Velocity component in X Direction 460m/s
Mass Flow Rate 7.89 kg/sec
Contour Wall Viscous Force -55.44152 N
Contour wall static pressure with Y Axis Exported from Fluent as Excel
sheet and prepared to be
imported to Matlab APPENDIX
C (YPContour.xlsx)
3.1.4 Thrust calculations
Using the aerospike thrust relations presented in previous section Matlab code is
written to calculate the total thrust force produced by full spike nozzle.
According to CFD fluent outputs introduced previously the static pressure output data
are imported to excel sheet then is integrated using Matlab code at APPENDIX C then
the rest of the thrust components are calculated and listed in (Table 3.4).
Table 3.4: Full spike nozzle thrust Matlab code outputs.

FThruster 8.4993e+03 N
FCenterbody 5.9048e+03 N
FViscous -55.44152 N
Total Thrust 1.4349e+04 N
Specific Impulse 185.3822 s
Result Discussion:
The Nozzle Produces a total pressure thrust force in the axial direction of about 1.464
tf. The Exit Mach number of the flow is 3.3 which deviates from the theoretical value
(3,17) about 4%. Also, as can be seen clearly the flow is optimum expanded as the
flow exits parallel to the horizontal axis. Moreover, From the pressure contours it can
be seen clearly that the aerospike nozzle has an outstanding feature of compensating
automatically to the outer pressure. Also, the deviation between the theoretical result
and CFD results are clearly due to the assumptions behind each solver. The CFD
solution uses density-based solver and (2eqn) K-epsilon viscous and uses the
geometric condition that the nozzle has an axis of symmetry to rotate the solution about
360° (axisymmetric), while Angelino method assumes 2D geometry. From previous
sections it is discussed that an aerospike nozzle should be designed with higher
27
expansion ratio as possible with little overexpansion to give an overall better
performance aver all the whole altitude. Since an over expanded aerospike nozzle is
away better than a bell nozzle having the same expansion ratio. And an under expanded
aerospike nozzle is not a lot better than an under expanded nozzle has the same
expansion ratio operating on the same altitude. Hence, this nozzle is accepted to
complete the rest of the research with as the flow is optimum expanded to the given
ambient pressure. From Figure B.7 it can be seen that it converged smoothly after 7155
iterations which indicates suitable mesh and boundary conditions.
3.2 40% Truncated Aerospike Nozzle
In this section a 40% Truncated version of the Full aerospike nozzle discussed in the
previous section is designed and analyzed using CFD, Total thrust, Specific impulse
calculated using Matlab using CFD output data. Plug 3D Model is generated using
Solid works to calculate the nozzle mass.
3.2.1 Cad model

From Angelino method used in the Matlab code in APPENDIX. A, the full aerospike
nozzle is drawn and 40% Truncated (Figure 3.6)
Figure 3.6 : 40% truncated aerospike nozzle 2D dimensional sketch.
Using SolidWorks evaluation tool for just the plug part (Figure D.2) using steel density
28
3.2.2 Cfd mesh tool
3.2.2.1 Mesh setup
General mash setting from (Table 3.1) is re applied to this configuration then followed
with local settings of (Table 3.5) then boundary naming is set as (Figure D.3).
Figure 3.7 : 40% truncated aerospike nozzle mesh sectioning.
Table 3.5 : 40% Truncated aerospike nozzle face & edge mesh settings.
Face A 1mm Hard
Face B 0.5mm Hard
Chamber)
3.2.2.2 Mesh output
Figure 3.8 : 40% truncated aerospike nozzle mesh map.
29
element density near the contour and the base. It can be seen from (Figures D.4-7)
most of the elements shown in (Table 3.6) has quality and orthogonal quality near the
one while maintaining most of the elements’ skewness near zero which indicates a
high mesh overall quality.
Table 3.6 : 40% Truncated aerospike element & node mesh number.
Nodes 79037
Elements 77732
3.2.3 Cfd fluent
Figure 3.9: 40% truncated aerospike nozzle Mach contours.
30
Figure 3.10: 40% truncated aerospike nozzle static pressure contours.
As seen from streamlines and Mach lines of Figures D.10,11 & Figure 3.9 the flow
still leaves the lip of the nozzle almost straight parallel to the nozzle axis which
indicates an optimum flow expansion at the given ambient conditions. Also, it can be
noticed that the flow treats the side boundaries as a fixed barrier since the far side
boundaries are assumed to be walls as the engine is assumed to operate in a wind
tunnel. It can be shown that in Figure 3.10 the all high-pressure values that are marked
in red and more than 200000pascal are covered with the contour walls while contour
wall regions that have lower pressure values are truncated. It can be noticed that a
small high-pressure zone is generated at the base. Fluent numerical values are listed in
(Table 3.7) to be used in Matlab thrust code in the next section.
Table 3.7 : 40% Truncated aerospike nozzle Matlab thrust code inputs.
Throat average Exit Velocity component in X 460m/s
Direction
Contour wall static pressure with Y Axis Exported from Fluent as Excel sheet
and prepared to be imported to Matlab
(YPContour.xlsx)
Base wall static pressure with Y Axis Exported from Fluent as Excel sheet
(YPBase.xlsx)
31
Using the aerospike thrust relations presented in previous section Matlab code is
written to calculate the total thrust force produced by the 40% Truncated aerospike
nozzle.
According to CFD fluent outputs introduced previously the static pressure output data
are imported to excel sheet then is integrated using Matlab code at APPENDIX E then
the rest of the thrust components are calculated and listed in (Table 3.8).
Table 3.8 : 40% Truncated aerospike nozzle Matlab thrust code outputs.
Fthruster 8.4993e+03 N
FViscous -50.51 N
FBase 9.1162 N
Result Discussion:
When we compare the results to the previous Full aerospike nozzle, we find that
although we cut the center body to 40%, the centerbody thrust increased. That is
because by the end of the contour at the full nozzle the pressure reaches small values
that are slightly less than the ambient which generates negative thrust. By cutting 60%
of the centerbody we are minimize that negative thrust. Also, Base add a high-pressure
region which add thrust. It is also clear that the negative viscous force is reduced as
the wall was shortened. Moreover, as the volume of the plug is reduced the nozzle
overall mass is reduced too. Besides overall the total thrust and Specific impulse are
increased compared to the previous nozzle. Also, we notice that at the base area a very
high temperature region is formed and wakes are formed which decreases the base
thrust. From Figure D.8 it can be seen that the solution ended up oscillating around a
constant value which indicates enough accuracy to end the analysis after more than
18000 iterations.
3.3 20% Truncated Aerospike Nozzle

In this section a 20% Truncated version (Figure 3.11) of the Full aerospike nozzle
discussed in a previous section is designed and analyzed using CFD, Total thrust,
Specific impulse calculated using Matlab using CFD output data. Plug 3D Model is
generated using SolidWorks to calculate the nozzle mass. After that it is compared
with the 40% truncated nozzle.
32
3.3.1 Cad model
Figure 3.11 : 20% truncated aerospike nozzle 2D dimensional sketch.
Using SolidWorks evaluation tool for just the plug part (Figure D.2) using steel density
3.3.2 Cfd mesh tool

3.3.2.1 Mesh setup
with local settings of (Table 3.9) then boundary naming is set as (Figure F.3).
Figure 3.12 : 20% truncated aerospike nozzle mesh sectioning.
33
Table 3.9 : 20% Truncated aerospike nozzle face & edge mesh settings.
Face A 1mm Hard
Face B 0.5mm Hard
Chamber)
3.3.2.2 Mesh output
Figure 3.13 : 20% truncated aerospike nozzle mesh map.

As a result of the mesh strategy. A control surface with mesh map (Figure 3.13) is
obtained with high element density near the contour and the base. It can be seen from
(Figures F.4-7) most of the elements shown in (Table 3.10) has quality and orthogonal
quality near the one while maintaining most of the elements’ skewness near zero which
indicates a high mesh overall quality.
Table 3.10 : 20% Truncated aerospike nozzle node & element number.
Nodes 73032
Elements 71811
34
3.3.3 Cfd fluent
Figure 3. 14: 20% truncated aerospike nozzle Mach contours.
Figure 3.15 : 20% truncated aerospike nozzle static pressure contours.
As seen from streamlines and Mach lines of Figures F.10,11 & Figure 3.15 the flow
indicates an optimum flow expansion at the given ambient conditions. It can be shown
35
that in Figure 3.10 that all high-pressure values that are marked in red and more than
200000pascal are not totally covered with the contour walls while contour wall regions
that have lower pressure values are truncated. It can be noticed that a wide very high-
pressure zone is generated at the base. Fluent numerical values are listed in Table 3.11
to be used in Matlab thrust code in the next section.
Table 3.11 : 20% Truncated aerospike nozzle Matlab thrust code inputs.
Throat average Exit Velocity component in X Direction 460m/s
Contour wall static pressure with Y Axis Exported from Fluent as Excel
imported to Matlab
(YPContour.xlsx)
Base wall static pressure with Y Axis Exported from Fluent as Excel
imported to Matlab
(YPBase.xlsx)
Using the aerospike thrust relations presented in previous section, Matlab code is
written to calculate the total thrust force produced by the nozzle. According to CFD
fluent outputs introduced previously the static pressure output data are imported to
excel sheet then is integrated using Matlab code at APPENDIX G then the rest of the
thrust components are calculated and listed in (Table 3.12).
Table 3.12 : 20% Truncated aerospike nozzle Matlab thrust code outputs.
FViscous -40.61 N
FBase 163.4938 N
Total Thrust 1.4312+04 N
Result Discussion:
When we compare the results to the previous Full aerospike nozzle, we find that
comparing to the 40% truncated nozzle when we increase the truncation to 20%, we
start to lose thrust from the center body as regions has positive values of (P - Patm) are
36
cut. Also, Base area increases. Hence, base thrust increases. However, stronger wakes
are formed which causes less efficiency. It is clear that the negative viscous force is
reduced as the wall was shortened. As the volume of the plug is reduced the nozzle
overall mass is reduced too. As a result, Overall, the total thrust and Specific impulse
are decreased compared to the previous nozzle. We notice that at the base area a very
high temperature region is formed. Hence, As the overall performance of the 40%
truncated nozzle gives higher thrust and impulse, we are continuing the research with
40% Truncated Nozzle. From Figure F.8 it can be seen that it converged smoothly
after more than 4500 iterations which indicates suitable mesh and boundary conditions.
3.4 40%Truncated - Blind Central Hole
As this research aims to optimize the aerospike nozzle and increasing thrust and
impulse, we need to monitor regions which lower the thrust and modify them. As we
decided to complete the research with the 40% Truncated Nozzle. We are making
further modifications on it. First, a source of low thrust is its base region. And the
major reason is the strong wakes formed. As an approach to reduce this effect a blind
hole is added to the center of the nozzle then analyzed and studied (Figure 3.16).
3.4.1 Cad model
Figure 3.16 : 40% truncated-blind central hole aerospike nozzle 2D dimensional

sketch.
Using SolidWorks evaluation tool for just the plug part (Figure H.2) using steel density
37
3.4.2 Cfd mesh tool
3.4.2.1 Mesh setup
General mash setting from Table 3.1 is re applied to this configuration then followed
with local settings of Table 3.13 then boundary naming is set as Figure H.3 shows.
Figure 3.17 : 40% truncated-blind central hole aerospike nozzle mesh sectioning.
Table 3.13 : 40% Truncated – blind central hole aerospike nozzle face & edge mesh
settings.
Face A 1mm Hard
Face B 0.5mm Hard
Edges C (Contour, Lip, Combustion Chamber, 0.1mm Hard
Base)
3.4.2.2 Mesh output
Figure 3.18 : 40% truncated-blind central hole aerospike nozzle mesh map.
38
element density near the contour, the base and bleed. It can be seen from Figures H.4-
7 most of the elements shown in (Table 3.14) has quality and orthogonal quality near
the one while maintaining most of the elements’ skewness near zero which indicates a
high mesh overall quality.
Table 3.14 : 40% Truncated – blind central hole aerospike nozzle node & element
number.
Nodes 82791
Elements 81365
3.4.3 Cfd fluent
Figure 3.19 : 40% truncated-blind central hole aerospike nozzle Mach contours.
39
Figure 3.20 : 40% truncated-blind central hole aerospike nozzle static pressure
contours.
As seen from streamlines and Mach lines of Figures H.10,11 & Figure 3.9 the flow
that in (Figure 3.20) the wakes generated at the base area is decreased as expected.
Hence the design achieved its main target. Fluent numerical values are listed in (Table
3.15) to be used in Matlab thrust code in the next section.
inputs.
Direction
Contour Wall Viscous Force -50.51N
(YPContour.xlsx)
Note that Base here is Base1 + Base2 ass shown and prepared to be imported to Matlab
in the boundary naming drawings (YPBase.xlsx)

Using the aerospike thrust relations presented in previous section, Matlab code is
written to calculate the total thrust force produced by the nozzle. According to CFD
40
fluent outputs introduced previously the static pressure output data are imported to
excel sheet then is integrated using Matlab code at APPENDIX I then the rest of the
thrust components are calculated and listed in (Table 3.16).
outputs.
FViscous -50.51 N
FBase 24.5517 N
Result Discussion:
When we compare the results to the 40% Truncated No-Hole nozzle we find that as
was expected, adding blind central hole increases the base thrust component as moving
the base far away from the wakes decreases the wakes affect. Also, it is noted that the
base which is mentioned here is the short wall Base1 + Base2. Wakes at Base 1 is
negligible as it is very short compared to the Base2. Hence, overall Thrust and Impulse
increase slightly compared to the 40% Truncated No-Hole Nozzle. From Figure H.8 it
can be seen that the solution suffered from high and low peaks at the beginning due to
the blind hole but it could converge smoothly after 5000 iterations which indicates
suitable mesh and boundary conditions.
3.5 40%Truncated – 0.98%Flux Central Straight Bleed

As it is discussed in the previous section adding a blind central hole decreases the base
wake effect and increases the thrust slightly. Here we are discussing adding a bleed
injection to this central hole (Figure 3.21). From a previous engineering work the
exhaust exits the fuel and oxidizer pump (Usually 1-2% of the main mass flow rate) is
being injected through a heat exchanger (Figure 3.22) through the base section. That
decreases the wake region and add amount of thrust.
41
Figure 3.21 : Turbine exhaust leaving the base for a truncated aerospike engine [18].
Figure 3.22 : Rocketdyne J-2T 250K Toroidal Aerospike [18].
For more analysis simplicity we assume that a full open central hole to the combustion
chamber with a pressure control valve to control the mass flow rate. However, this
assumption is the real case of small-scale rocket as there is no pumps, All the liquids
are kept pressurize in the tanks and a full hole to the main combustion chamber with
pressure reduction throat is applicable.
42
3.5.1 Cad model, mesh tool & boundary conditions
There are no changes from the previous nozzle (40% Truncated-Blind-Central Hole
Nozzle) as the only change is fluent boundary conditions (Figure 3.21). which are set
as following:
Boundary Condition:
Pressure Inlet: 4800000 Pascal
Pressure Inlet Total Temperature: 1773k
Base2: Mass Flow inlet of 0.97% (0.0767 kg/sec) of the main flux (7.89 Kg/sec)
Temperature of the bleed is same of combustion chamber.
Figure 3.23: 40%Truncated – 0.98%flux central straight bleed-Boundary conditions

definition.
43
3.5.2 CFD fluent
Figure 3.24 : 40%Truncated – 0.98%flux central straight bleed-Mach contours.
Figure 3.25: 40%Truncated – 0.98%flux central straight bleed-static pressure

contours.
As seen from streamlines and Mach lines of Figures J.2,4 & Figure 3.24 the flow still
leaves the lip of the nozzle almost straight parallel to the nozzle axis which indicates
an optimum flow expansion at the given ambient conditions. It can be shown that in
44
(Figure 3.25). It can be noticed that adding a bleed inject to the central hole has a great
effect on the wakes generated at the base zone as it is totally demolished and replaced
with high pressure region from the leaving exhaust. Fluent numerical values are listed
in (Table 3.17) to be used in Matlab thrust code in the next section.

inputs.
Direction
Bleed average Exit Velocity component in X 285m/s
Direction
Main Mass Flow Rate 7.89 kg/s
Bleed Mass Flow Rate 0.0767 kg/s
Bleed Wall Viscous Force -0.897 N
('YPContourNoBleed.xlsx) as it is
same of no bleed
Note that Base here is Base1 + Bleed exit and prepared to be imported to Matlab
section as shown in the boundary naming ('YPBase.xlsx)
drawings (Figure 3.23)

Using the aerospike thrust relations presented in a previous section Matlab code is
written APPENDIX K to calculate the total thrust force produced by the 40%
Truncated aerospike nozzle using CFD fluent outputs introduced previously in (Table
3.17). Then outputs are calculated and listed in (Table 3.18).

outputs.
FBleed_Momentum 21.8595 N
F Contour viscous -50.51 N
FBleed Viscous -0.8970 N
FBase 75.0693 N
Result Discussion:
When we compare the results to the 40% Truncated Blind central hole, we find that
as was expected, adding mass flow rate to the central hole decreases the wakes formed
at the base and increases the pressure at this region. Also, it is noted that the base which
45
is mentioned here is the short wall Base1 + Bleed Exit Section. We note that there are
a new two components added to the total thrust which are the bleed flow momentum
and the negative viscous force caused by the bleed passing the wall. As a result, Over
All Thrust increased and impulse decreased slightly because of the addition mass flow
rate.
3.6 Hybrid Aerospike-Conical Nozzle-40%Truncated – 2.9%Flux Central Bleed.
We see that through the previous design the exhaust of the fuel and oxidizer pump is
being injected through a central bleed. Also, this can be approached in small scale
rockets which do not have pumps by opening the bleed to the combustion chamber
with pressure suppression valve to control the mass flow rate. This method increased
total thrust slightly as it adds extra momentum and pressure components. But, it is
obvious that this method reduces the efficiency dramatically specially with increasing
the mass flow rate as the flow leaves the bleed with lots of energy that is not used
presented in high temperature as seen in the temperature contours (Figure J.3). This
section and the next section present a new concept that is first introduced in this
research. The aim of these concept is to maximize the nozzle thrust by increasing the
bleed mass flow rate while decreasing the energy loss of the bleed exhaust by passing
through Convergent-Divergent Nozzle. For simplicity a conical nozzle is chosen with
12 divergence degrees. The designed introduced in this section presents a 2.9% mass
flow rate of the primary nozzle flux. It should be noticed that in this concept the bleed
is fully open directly to the main combustion chamber without any pressure
suppression valves to reduce manufacturing complexity and to use the maximum
pressure of the combustion chamber to increase the mass flow rate and so thrust. So
mass flow rate is determined mainly by the Conical nozzle throat area as other
parameters are fixed. In this section we are analyzing this Hybrid Nozzle (Aerospike-
Conical) concept by passing 2.9% flux and with using expansion ration of 1.56
(Figure3.26).
46
3.6.1 Cad model
Figure 3.26 : Hybrid aerospikes conical nozzle-40%truncated – 2.9%flux central

bleed-2d dimensional sketch.
Using SolidWorks evaluation tool for just the plug part (Figure L.2) using steel density
3.6.2 Cfd mesh tool
3.6.2.1 Mesh setup
with local settings of Table 3.19 then boundary naming is set as Figure 3.27 with the
following setting:
Boundary Condition:
Base2: Pressure Inlet of 4800000 Pascal
47

bleed- boundary conditions definition.

bleed- face & edge mesh setting.
bleed- face & edge mesh setting.
Face A 1mm Hard
Face B 0.5mm Hard
Edges C (Contour, Lip, Combustion Chamber, Base, 0.1mm Hard
Conical Nozzle Divergent section)
48
3.6.2.2 Mesh output

bleed- mesh map.
element density near the contour, base and central conical nozzle. It can be seen from
(Figures L3-6) most of the elements shown in (Table 3.20) has quality and orthogonal
bleed- mesh element & node number.
Nodes 83821
Elements 82307
49
3.6.3 Cfd fluent

bleed- Mach contours.

bleed- static pressure contours.
As seen from streamlines and Mach lines of (Figures L.9,10) & (Figure 3.30) the flow
indicates an optimum flow expansion at the given ambient conditions. Also, we can
see very high Mach values that reaches 4.4 as a result of the interaction between the
50
central flow and primary flow at high velocities. It can be shown that conical nozzle
expanded the flow so it leaves with lower pressure but still higher than ambient which
indicates a low performance (Figure 3.31). Also, from temperature contours of Figure
L.15 it can be seen that the exhaust exits the nozzle with a relatively high temperature
which means losses are exits and a higher expansion ratio is needed to achieve more
optimum nozzle. Fluent numerical values are listed in (Table 3.21) to be used in Matlab
thrust code in the next section.
bleed- Matlab thrust code inputs.
Direction
Bleed average Exit Velocity component in X 1200m/s (From fluent Chart)
Direction
Bleed Wall Viscous Force -1.45 N
same of no bleed
Note that Base here is Base1 + Conical Nozzle and prepared to be imported to Matlab
exit section as shown in the boundary naming ('YPBase.xlsx)
drawings

Using the aerospike thrust relations and conical Nozzle thrust relation presented in
previous section, Matlab code is written APPENDIX M to calculate the total thrust
force produced by the nozzle
According to CFD fluent outputs introduced previously in (Table 3.21) the below
outputs are calculated (Table 3.22) using APPENDIX M.
bleed- Matlab thrust code outputs.
FBleed Momentum 276 N
FBleed Viscous -1.45 N
FBase 13.7153 N
51
Result Discussion:
When we compare the results this Nozzle (Hybrid Aerospike Conical Nozzle-
40%Truncated – 2.9%Flux Central Bleed) to the previous nozzle (40%Truncated –
0.98%Flux Central Straight Bleed) we find that as was expected, the Hybrid Aerospike
Conical nozzle increased the bleed thrust as it increased the momentum of the exhaust
by expanding the flow. So, the flow is faster more than four times than the previous
design. It is also noticed that the base thrust is reduced due to the expansion which
reduced the pressure but increased momentum. Over all momentum has covered the
pressure loss and add much extra thrust. Also, the conical nozzle exhaust is under
expanded which means there are still losses presented in heat exiting the conical
nozzle. That requires bigger expansion ration to be more optimum. Moreover, we see
the exit area of the conical nozzle a lot smaller than the plug base area which causes
wakes at the Base reducing again the base pressure thrust. From Figure L.7 it can be
seen that it converged smoothly after 2500 iterations which indicates suitable mesh
and boundary conditions. For the next design more optimum nozzle is presented that
solves these problems and decreases losses.
3.7 Hybrid Aerospike Conical Nozzle-40%Truncated – 5.9%Flux Central Bleed.
We see that through the previous design the flow was under expanded due to low
expansion ratio. Lots of losses presented in heat leaves the conical nozzle. Also, the
exit area was a lot smaller than the base which caused waked that reduces thrust. In
this design we are trying to push the nozzle to its limits and get maximum thrust by
solving the previous nozzle problems and maximize its mass flow rate. It is known that
the pressure is fixed since it is opened to the combustion chamber. So the way to
increase the mass flow rate is to maximize throat area. Using the Isentropic relations
between the combustion chamber pressure and the ambient pressure we get that the
expansion ratio of 6.758.
And by knowing that the maximum conical nozzle exit area due to geometry
limitations is 30mm so the throat dimeter is calculated to be 11.54mm (Figure 3.32).
52
3.7.1 Cad model

bleed- 2D dimensional drawing.
Using SolidWorks evaluation tool for just the plug part (Figure N.2) using steel density
3.7.2 Cfd mesh tool
3.7.2.1 Mesh setup
with local settings of (Table 3.23) applied to (Figure 3.34) then boundary naming is
set as (Figure 3.33) as following:
Base2: Pressure Inlet of 4800000 Pascal
53
bleed- boundary conditions definition.

bleed- mesh sectioning.
bleed- mesh face & edge setting.
Face A 1mm Hard
Face B 0.5mm Hard
Chamber, Base, Conical Nozzle Divergent
& Convergent section)
54
3.7.2.2 Mesh output

bleed- mesh map.
element density near the contour, the base and the conical nozzle. It can be seen from
(Figures N.3-6) most of the elements shown in (Table 3.24) has quality and orthogonal
bleed- element & node number.
Nodes 89504
Elements 87825
55
3.7.3 Cfd fluent

bleed-Mach contours.

bleed-static pressure contours.
56
As seen from streamlines and Mach lines of Figures D.10,11 & Figure 3.9 the flow
that in Figure 3.37 the exhaust leaves the conical nozzle with almost ambient pressure
which indicates high performance and optimum expansion. Also, from Figure N.11 it
can be seen the flow exiting the conical flow with a lot lower temperature than the
previous design which indicates lower losses that most of the temperature is converted
to momentum through the expansion section. Fluent numerical values are listed in
(Table 3.25) to be used in Matlab thrust code in the next section.
Table 3.25 : Hybrid aerospike conical nozzle-40%truncated – 5.9%flux central

bleed- Matlab thrust code inputs.
Direction
Bleed average Exit Velocity component in X 1575m/s (From fluent Chart)
Direction
Bleed Wall Viscous Force -9 N
same of no bleed
Note that Base here is Base1 + Conical Nozzle and prepared to be imported to Matlab
exit section as shown in the boundary naming ('YPBase.xlsx)
drawings
Using the aerospike thrust relations and conical Nozzle thrust relation presented in a
previous section. Matlab code is written APPENDIX O to calculate the total thrust
force produced by the nozzle. According to CFD fluent outputs introduced previously
in (Table 3.25) the below outputs in (Table 3.26) are calculated.
57
bleed- Matlab thrust code outputs.
FBleed_Momentum 733.1625 N
FBleedViscous -9 N
FBase -22 N
Result Discussion:
From Figure N.7 it can be seen that it converged smoothly after 2500 iterations which
indicates suitable mesh and boundary conditions. We can notice that clearly this nozzle
increased the thrust dramatically. It is worth to say that the thrust increased by 4.7%
compared to the no-bleed 40%Truncated nozzle and by 4.8% compared to the full
aerospike Nozzle. When we are comparing the specific impulse, we find that it is 1%
less compared to the no-bleed 40%Truncated nozzle and 0.9% less compared to the
full aerospike Nozzle. After determining the expansion ratio using the isentropic
relations, we notice that according to CFD analysis the flow exits the conical nozzle at
pressure lower than the ambient about 4.4% which is almost optimum but caused a
very small negative base pressure about -9N which is negligible. Also, we can notice
that compared to the full nozzle design the thrust increased dramatically but the
impulse decreased slightly due to the nature of the conical nozzle that the flow exits
the nozzle with a 12° angle which is not parallel to the horizontal axis. That means
there is losses due to the exit angle. That can be solved by using Bell shaped conical
nozzle instead in future. Finally, it is clear that the Hybrid Aerospike-Conical Nozzle
has showed great potential by increasing the thrust dramatically which can help a lot
to decrease the number of engines used in rockets that requires high thrust and lots of
engines. Normally, if it is wanted to increase a rocket engine thrust, throat area (so
nozzle dimensions) increases or combustion pressure needs to increase instead which
cause problems to structure. Using the concept introduced in this research we achieve
higher thrust using the same combustion chamber without increasing the nozzle
dimensions or combustion pressure. As an example, if a rocket uses twenty Aerospike
engines to lift off, using the hybrid engine it can achieve the same performance using
nineteen engines and even less compared to bell nozzles.
58
3.8 Nozzle Performance Summary
As a brief of this section an aerospike nozzle is optimized through different

configurations applied while obtaining different thrust and impulse which indicates
main two keys of nozzle design (Table 3.27).
59
Table 3.27 : Nozzle Performance Summary.
Full Spike 40% 20% 40%Truncated 40%Truncated Hybrid Aerospike Hybrid Aerospike
Parameter Nozzle Truncated Truncated - Blind – 0.98%Flux Conical Nozzle- Conical Nozzle-
Aerospike Aerospike Central Hole Central 40%Truncated – 40%Truncated –
Nozzle Nozzle Straight Bleed 2.9%Flux Central 5.9%Flux Central
Bleed. Bleed.
Fthruster (KN) 8.5 8.5 8.5 8.5 8.5 8.5 8.5

FCenterbody (KN) 5.90e 5.91 5.69 5.91e 5.91 5.91 5.91
FBleed Momentum (N) 0 0 0 0 21.86 276 733.16
FContour viscous (N) -55.44152 -50.51 -40.61 -50.51 -50.51 -50.51 -50.51
FBleed Viscous (N) 0 0 0 0 -0.8970 -1.45 -9
FBase (N) 0 9.1 163.5 24.5 75 13.7 -22
Total Thrust (KN) 14.34 14.37 14.31 14.38 14.45 14.65 15.05
Specific Impulse s 185.4 185.7 184.9 185.9 185 184 183.7
Nozzle Plug Mass (g) 1582 1398 1027 1041 1041 1186 1161
60
4. STEERING CONTROL
A missile or space vehicle requires a significant amount of steering control- as it flies

through atmospheric winds and performs the pitch, yaw, and roll maneuvers necessary
in the performance of its mission. Most liquid-propelled vehicles are steered by engine
gimbaling; that is, the entire chamber and nozzle assembly is moved relative to the rest
of the vehicle so that the direction of thrusting is changed. Moving a solid-rocket
chamber relative to the vehicle is a large task because the chamber is a major portion
of the vehicle and contains all of the rocket's propellant. The combustion chamber is
not separate from the propellant tankage. Solid rockets are therefore steered by moving
the nozzle alone, by moving the exit cone of the nozzle alone, or by changing the
direction of the exhaust jet coming from the nozzle. Any method of controlling the
direction of thrusting in relation to the engine or the vehicle is termed "thrust vector
control" or TVC .
Moving the entire nozzle or the exit cone has been done successfully in many missiles
(Minuteman, Skybolt, air-to-air missiles). Deflection of the exhaust-gas jet alone has
also been accomplished by placing obstacles such as vanes or tabs in the nozzle to
disturb the exhaust flow pattern, or by injecting a fluid (gas or liquid) through the
nozzle wall at right angles to the main gas stream. In this way, the jet and the thrust
direction are deflected a few degrees off the vehicle centerline. This method of steering
is used in such operational rocket vehicles as Minuteman n, Polaris, and the 120-inch
boosters for the TITAN III C. Another way to steer a rocket is achieved by using
A vernier thruster [19] (Figure 4.4) which is a rocket engine used on a spacecraft for
fine adjustments to the attitude or velocity of a spacecraft. On space vehicles with two
sizes of attitude control thrusters, the main ACS (Attitude Control System) thrusters
are used for larger movements, while the verniers are reserved for smaller adjustments.
Due to their weight and the extra plumbing required for their operation, vernier rockets
are seldom used in new designs. Instead, as modern rocket engines gained better
control, larger thrusters could also be fired for very short pulses, resulting in the same
change of momentum as a longer thrust from a smaller thruster.
Another method of steering for rocket vehicles involves the use of aerodynamic
surfaces (vanes, fins, or canards) which give steering-control forces through lift, like
an airplane wing. A vehicle with this kind of control needs no thrust vector control in
61
the propulsion system (e. g. most air-to-air and ground-to-air missiles). However,
aerodynamic control can occur only in the atmosphere and while the vehicle has
sufficient velocity through the air. Aerodynamic steering may be combined with TVC;
the TVC provides steering control near the ground before the vehicle has built up
velocity, and on the edge of the atmosphere or in space where a wing becomes useless
[20].
Figure 4.1: Movable nozzle [20].
Figure 4.2: Jet tabs on a rocket developed by Lockheed for the U. S. Air Force [20].
62
Figure 4.3 : Secondary injection [20].
Figure 4.4 : Auxiliary "Vernier" thrusters [19].
63
Figure 4.5 : Aerodynamic control. Nike missile with fin stabilizers and canard
steering [20].
To summaries, in order to Steer a rocket one of the following methods is used:
 Gimbaled engine(s) or nozzle(s)

 Reactive fluid injection
 Auxiliary "Vernier" thrusters
 Exhaust vanes or taps also known as jet vanes
 fins, or canards.
As it is discussed Using Reactive fluid injection does not include any massive
moving actuators like gimbaled engines or nozzle method. Also, it does not have
any moving control surfaces like exhaust vanes, taps, fins or canards. Also, this
method presents the most cost-effective way to steer a rocket. Hence, the
secondary injection method is studied, analyzed and optimized on the previous
optimized aerospike nozzle.
64
In this section a single 4.6mm circular injection is added to the previous optimized
40% truncated aerospike nozzle. The injector is placed at 90% of the plug length. The
injection pressure and temperature are set to be equal to the combustion chamber while
the mass flow rate in return is expected to be 1% of the main mass flow rate. It is noted
that since adding secondary injection will make the nozzle lose its axisymmetric
feature. 2D analysis is not possible. Instead a 3D CFD analysis is performed with XY
symmetry as a single injector is added (Figure 4.6). Also, a control volume is prepared
for fluent as shown in (Figure 4.7) and (Figure P.1).
4.1.1 Cad model

Nozzle-2D dimensional drawing.
65
4.1.2 Cfd mesh tool
4.1.2.1 Mesh setup

with local settings of Table 4.1 with Figures 4.8,9 and local settings of Table 4.2 with
Figures 4.10,11. Also the control volume is divided into six partitions as shown in
Figure P.2 and Figure P.3.

Nozzle- control volume 2D dimensional sketch.
66
Nozzle- body & face mesh setting.

Nozzle- detailed body & face mesh setting.
Table 4.1 : 90% positioned Secondary Injection on 40% Truncated aerospike
Nozzle- body & face mesh setting.
Face or Body Property
MultiZone A Hex
Face Sizing B Element Size = 0.5mm
Face Meshing C Mapped Face Meshing
Body Sizing D Element size = 2mm
Face Meshing E Mapped Face Meshing
Face Sizing F Element Size =0.5mm
MultiZone G Hex
Body Sizing H Element Size = 0.1mm
Face Meshing I Mapped Face Meshing
MultiZone J Hex
67
Nozzle- edge mesh setting.
Figure 4.11: 90% positioned Secondary Injection on 40% Truncated aerospike

Nozzle-detailed edge mesh setting.
68
Table 4.2 : 40% Truncated aerospike nozzle-90% secondary jet positioning- edge
mesh setting.
Edge Property
Edge Sizing A Element Sizing = 0.5mm
Edge Sizing B Division No = 45, Bias = 7
Edge Sizing C 2edge, Division No= 137
Edge Sizing D 2edge, Division No=100, Bias=5
Edge Sizing F Division No=25, Bias=8
Edge Sizing G 2edge, Division No=137
Edge Sizing H edge, Division No=274
Edge Sizing I Element size=0.5mm
4.1.2.2 Mesh output
As a result of the mesh strategy a control surface Figure 4.12 and Figures P.4,5 are
obtained with high element density near the contour, the base and the secondary inject.
It can be seen from Figures P.6-12 most of the elements shown in Table 4.3 have
quality and orthogonal quality near the one while maintaining most of the elements’
skewness near zero which indicates a high mesh overall quality.

Nozzle- mesh map.
69
Table 4. 3 : Mesh element & nodes number.
Nodes 14868992
Elements 3599402
4.1.3 Cfd fluent

Nozzle- Mach contours.

Nozzle- sectional Mach contours at secondary jet center.
70
Nozzle- pressure contours-ISO.
As seen from streamlines and Mach lines of Figures P.14,15 & Figures 4.13,14 an
aggressive bow shock wave is generated in front of the inject due to the interaction of
two supersonic flow. That bow shock produced a high-pressure zone in front of it
which increases the side force while generating a low-pressure zone downstream
which weaken the side force as seen in Figure 4.15. Numerical values and Matlab
thrust side force and thrust outputs are listed in Table 4.4 and explained in the next
section.
4.1.4 Side force calculations
Side force contents of three values (Injection momentum force + Injection exit pressure
+ The amplification amount produced by the upper and lower surface pressure
difference caused by the bow shock wave). A Matlab Code in APPENDIX Q is written
to calculate the side force using the CFD exported EXCEL data.
71
Nozzle- resultant side force map.
Result Discussion:
From Figure P.13 it can be seen that the solution ended up oscillating around a constant
value which indicates enough accuracy to end the analysis after more than 8000
iterations. In order to present the numerical outputs, the phenomena itself should be
explained; a side secondary jet is chosen to be perpendicular to the nozzle axis so the
exhaust momentum gives the maximum side force contribution. Secondary inject
causes Bow shock to the primary flow which cause high pressure zone around the
inject opening tends to diminish away from the leading edge of the hole. a low-pressure
region behind caused by over expansion of the primary inject, this region affects
directly the base area since the inject opening is very close to the end of the plug and
the base. Which causes force opposes the main thrust at the base itself. It should be
noticed that all these forces including the main thrust force are deviates from the
centroid which causes momentum should be taken in consideration. Hence, and from
Table 4.4 and Figure 4.16 to summarize. The forces acting on the nozzle in Y (side)
direction are:
1- Side Force in Y direction caused by the inject gas momentum (F1)
acting at Y distance of X1=0.05828m from the contour start.
72
2- Side Force in Y direction caused by pressure difference between the
upper and lower plug surfaces including the high pressure inject throat
opening + the bow shock amplification resultant. (F2) acting at Y
distance of X2=0.0528m from the contour start.
3- Primary thrust force (Fthruster) in X direction caused by the primary
exhaust momentum leaving the throat acting on the centroid.
4- Primary thrust force (FJet Pressure) in X direction caused by the primary
exhaust pressure leaving the throat acting on the centroid.
5- Primary thrust force (F4) in X direction caused by pressure around the
plug including the high pressure inject throat opening + the bow shock
effect and deviates from the centroid by Y1=6.0912e-05m
6- Base Pressure force (F3) caused by exhaust in the base area in X
direction and deviates from the centroid by Y2=4.1965e-04m
7- Viscous force acting on the centroid (Fviscous (N)).
Resultant Side Force:
The total side force (Total Fy = -125.2891 N) acting at (Xr=0.0551m) distance from
the plug start which is 85.0588% of the plug length. Also, amplification factor (which
is the ratio of the Total side force to the side force if there is no primary force effect)
of 1.395 is resulted and specific impulse of the side inject flow of 167.3862 s is
calculated.
Table 4.4 : 20% secondary Jet position Performance outputs.

Fthruster (N) -8.4993e+03
Fviscous (N) 50.5100
F1 -52.1892
FJet Pressure (N) -37.5975
F3 18.3868
Y2 4.1965e-04
F2 -73.0999
F4 -5.7687e+03
Y1 6.0912e-05
X2 0.0528
X1 58.28
Total Fy (N) -125.2891
Xr (m) 0.0551
Amplification Factor 1.395
Total Thrust (N) -1.4199e+04
Specific Impulse for Primary Flow (s) 183.4488
Specific Impulse for Secondary Flow (s) 167.3862
Secondary Jet Mass Flow Rate kg/s 0.0763
Ratio of Secondary Flow Rate to primary 0.967%
One
73
Design & Analysis
A modified design is being investigated to study the effect of the position of the
secondary inject on the resultant side force. In this section the secondary inject is being
positioned at 20% of the nozzle contour length (Figure 4.17) then analyzed using CFD.
Fluent pressure contours appear at Figure 4.18 which indicates again a bow shock in
front of the secondary jet but this time the bow shock is weaker since the primary flow
velocity lower at this position. Hence, the high-pressure region in front of the jet is
weaker. On the other hand, the low-pressure zone downstream the jet is very wide
which decreased the total side force a lot to 94.9366 N. and gave secondary jet specific
impulse of 126.94 s and Amplification Factor of 0.6386.

nozzle-2D dimensional sketch.
74
nozzle- static pressure contours-ISO.
4.3 Secondary Jet Position Effect on Aerospike Nozzle Summary
As a brief, the results of three configurations are being compared to see the
optimization results clearly in Table 4.5. 20% positioned jet, 90% positioned jet and a
third nozzle without any primary flow to see the side force of the side jet alone to be
able to calculate the amplification factor which is the ratio of the total side force to the
side force if there is no primary flow. The results show maximum side force when
positioning the side jet at 90% of the contour as was expected from the previous
analysis discussion and the pressure contours.
Table 4.5 : Secondary jet performance comparison for different configurations.

Jet Position Total Side Jet Specific Amplification
Force Impulse Factor
20% 94.9366 N 126.94s 1.0573
90% 125.2891N 167.3862 1.395
Jet Without Primary Flow 89.7867N 119.9 1
75
76
5. CONCLUSION
An Aerospike Nozzle plug contour is designed according to Angelino

approximation method. The contour point is determined using a written Matlab
code to get the optimum performance in the ambient atmosphere of 101325 Pa.
The combustion pressure and temperature is set to ~700 PSI and ~1500C. Nozzle
is imported to SolidWorks in order to draw the boundaries required for Ansys.
Since the nozzle is Axisymmetric around the nozzle main axis a 2D Ansys
Analysis is performed. Nozzle is analyzed under various truncation percentages
(Full, 40%, 20%) it is found that truncation of 40% gives the optimum performance
since the expanded downstream flow has a very low pressure near or little less than
the atmosphere while truncation creating a base area which add some thrust to the
nozzle. Also increasing the truncation to higher than 40% decreases the
performance since a high-pressure zone are delaminated and replaced by base low-
pressure zone. From thermal point of view 40% truncation is better than full plug
since the full spike tip has minimum wall mount which will be affected
dramatically from the exhaust high temperature.
A central hole is added and analyzed. It is found that adding a blind hole increases
the performance since the wall is moved far back from the base high vortices and
low-pressure zone. Also adding bleed gas to the central hole showed greater
performance since the bleed gas eliminate the vortices generation at the base.
Also, a new concept is new introduced in the research has been analyzed using
CFD and showed significant increase of thrust which is required and will result in
reduction in number of engines used in a particular rocket since a smaller number
of engines would produce the same amount of thrust. This nozzle is a “Hybrid
Aerospike-Conical Nozzle”. The Design goal is to use the unused bleed gas
thermal energy by expanding the gas through a conical nozzle while giving the
bleed maximum flux by opening the central hole to the main combustion chamber
and by increasing the throat diameter to maximum while keeping the expansion
ration of the conical nozzle to optimum to work between the 700 Psi combustion
chamber and the ambient. The CFD Results showed a dramatic thrust increase of
4.7%.
A secondary injections method is used to steer control the nozzle due to the
manufacturing simplicity since no moving hydraulics, gimbals or moving actuator
77
are required except for valves for each inject. A ~1% mass flow rate of the primary
flow is applied through a 4.6mm inject opening to the main combustion chamber
pressure. Different inlet positions are studied. 20% and 90% distances measured
from the start of the 40% truncated aerospike nozzle length is applied. The 90%
position showed clearly higher performance, side force and impulse since the
interaction between the primary exhaust and the jet create a bow shock which
increases the pressure in front of the jet opening while demolish back downstream
of the jet creating a very low-pressure zone that encounter the jet thruster function.
Positioning the jet at 20% upstream causes a long zone of this low-pressure area
which causes 1.0573 amplification factor. Since the amplification factor is very
close to one, it can be concluded that the low-pressure area has almost eliminated
the high pressure bow shock area effect. Hence, eliminating this downstream zone
to minimum increases the performance of the secondary jet. So, 90% position
showed the maximum performance and amplification factor. Another reason 90%
jet position is better that moving the jet to the end of the contour would maximize
the area projection parallel to the rocket axis which will maximize the side force
from geometry point of view. Another reason that moving downstream creating
stronger bow shock due to higher Mach number downstream. Hence, creating
higher pressure zone. It is also should be noted that secondary jets optimum
position of an aerospike nozzle totally differs from the conical and Bell nozzles. In
conical nozzle it is better to keep the secondary jet close to the throat since the low
downstream pressure zone are reinforcing the side force since the nozzle wall is
outside not inside the flow. Hence, for aerospike nozzles 90% position secondary
jet is better while for conical nozzles 20% position is better. For better performance
in future work, central Bell nozzle can be worked on instead of the conical central
bleed nozzle. It should improve the performance since the exhaust exits the nozzle
at very low or zero angle instead of 12 degrees in the conical nozzle. That will
direct the whole exhaust momentum to parallel to main axis of the nozzle which
will increase thrust. Also, secondary jets number around the nozzle can be studied.
Which is better, three inlets with 120 degrees between of four jets with 90 degrees
between. As the bow shocks created from each nozzle can affect the other bow
shock created from other nozzles. The question is, is it better to keep them far as
much as possible to eliminate interaction by the 120° angle. Or it is better to keep
them close and allow interaction by decreasing the angle to 90°.
78
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81
82
APPENDICES
APPENDIX A: Full spike contour design Matlab code
clc;
close all;
clear all;
%%INPUTS
alfa=1.4;
pe=101325;
pt=700*6894.7572932;
rt=0.05;
rb=0;
%% BOUNDRIES
Me=sqrt((((pe./pt).^((alfa-1)./(-alfa)))-1).*(2./(alfa-1)))
%Isentropic relations
thetat=(sqrt((alfa+1)./(alfa-1)).*atan(sqrt((alfa-1).*(Me.^2-
1)./(alfa+1)))-atan(sqrt(Me.^2-1)));%.*180./pi Expansion fan
ExpRatio=(((alfa+1)/2).^(-(alfa+1)/(2.*alfa-1))).*((1+(((alfa-
1).*Me.^2)./2)).^((alfa+1)./(2.*(alfa-1)))./Me) %Isentropic
relations
re=sqrt((((rt.^2).*(ExpRatio./cos(thetat))-
rb^2)./(ExpRatio./cos(thetat)-1)))%Angelino
At=pi.*(re.^2-rt.^2)./(cos(thetat))%Angelino
Ae=At.*(((alfa+1)/2).^(-(alfa+1)/(2.*alfa-1))).*((1+(((alfa-
1).*Me.^2)./2)).^((alfa+1)./(2.*(alfa-1)))./Me) %Isentropic
relations
%% CONTOUR CALCULATIONS
M = 1 : 0.001 : Me;
A=At.*(((alfa+1)/2).^(-(alfa+1)/(2.*alfa-1))).*((1+(((alfa-
1).*M.^2)./2)).^((alfa+1)./(2.*(alfa-1)))./M); %Isentropic relations
83
Meu=asin(1./M);
theta=(sqrt((alfa+1)./(alfa-1)).*atan(sqrt((alfa-1).*(M.^2-
1)./(alfa+1)))-atan(sqrt(M.^2-1)));
L=(re-sqrt(re.^2-(A.*M.*sin(Meu+thetat-
theta)./pi)))./(sin(Meu+thetat-theta));
x=L.*cos(Meu+thetat-theta);
y=L.*sin(Meu+thetat-theta);
%% PLOTTING
plot(x,y)
xlim([-0.1 0.2])
ylim([-0.1 0.2])
m= y(1)/x(1);
Xt= linspace(-0.01,0);
Yt= (-1./m).*Xt;
line(Xt,Yt)
Xs= linspace(0,1);
Re=re+Xs.*0;
line(Xs,Re)
--------------------------------------------------------------------------------
------------------
OUTPUTS:
Me = 3.1747
ExpRatio = 6.7751
re = 0.0524
At = 0.0013
Ae = 0.0086
84
APPENDIX B: Full spike nozzle Figures.
Figure B.1 : Full spike nozzle CAD model.
Figure B 2 : Full spike plug CAD model.
Figure B.3 : Full spike nozzle boundary conditions definition.
85
Figure B.4: Full spike nozzle element quality contours.
Figure B.5 : Full spike nozzle element quality chart.
Figure B.6: Full spike nozzle skewness Chart.
86
Figure B.7: Full spike nozzle orthogonal quality chart.
Figure B.8: Full spike nozzle fluent convergence graph.
Figure B.9: Full spike nozzle velocity contours.
87
Figure B.10: Full spike nozzle unfilled Mach lines.
Figure B.11 : Full spike nozzle streamlines.
88
Figure B.12: Full spike nozzle temperature contours.
Figure B.13 : Full spike nozzle wall temperature with y axis.
89
Figure B.14: Full spike nozzle wall adjacent static pressure with y axis.
Figure B.15 : Full spike nozzle wall Adjacent flow density with y axis.
90
Figure B.16: Full spike nozzle wall adjacent shear force with x axis.
Figure B.17 : Full spike nozzle throat exit velocity component in x direction.
91
APPENDIX C: Full aerospike nozzle thrust code.
clc
close all
clear all
Y= xlsread('YPContour.xlsx','A:A');
P= xlsread('YPContour.xlsx','B:B');
Po=4800000;
Patm=101325;
flux=7.89;
Aty= pi*(0.05234828201^2-0.04909613294^2); %throat area projection in Y
direction
Vx=460; % Throat average Exit Velocity component in X Direction
n = size(Y)
i = 1;
Fcenterbody=0;
Fthruster=0;
Fthruster = (flux*Vx)+(Po-Patm)*Aty
% CenterBody Thrust Calculation
while 1727 > i+1
dAy=pi.*(Y(i+1).^2-Y(i).^2);
dPavg=((P(i+1)+P(i))./2)-Patm;
Fcenterbody=dPavg.*dAy+Fcenterbody;
i = i+1;
end
Fcenterbody=Fcenterbody
% Thruster Thrust Calculation
Fviscous= -55.44152
Total_Thrust = Fthruster + Fcenterbody + Fviscous
Specific_Impulse = Total_Thrust/(flux*9.81)
92
APPENDIX D: 40% Truncated Aerospike Nozzle.
Figure D.1: 40% Truncated aerospike nozzle CAD model.
Figure D.2: 40% Truncated aerospike plug CAD model.
93
Figure D.3: 40% Truncated aerospike nozzle boundary condition definition.
Figure D.4: 40% Truncated aerospike nozzle element quality contours.
Figure D.5: 40% Truncated aerospike nozzle element quality chart.
94
Figure D.6: 40% Truncated aerospike nozzle skewness chart.
Figure D.7: 40% Truncated aerospike nozzle orthogonal quality chart.
Figure D.8: 40% Truncated aerospike nozzle fluent convergence graph.
95
Figure D.9: 40% Truncated aerospike nozzle velocity contours.
Figure D.10: 40% Truncated aerospike nozzle Mach lines.
96
Figure D.11: 40% Truncated aerospike nozzle streamlines.
Figure D.12: 40% Truncated aerospike nozzle temperature contours K.
97
Figure D.13: 40% Truncated aerospike nozzle wall temperature with y axis.
Figure D 14: 40% Truncated aerospike nozzle wall adjacent static pressure with y.
axis
98
Figure D.15: 40% truncated aerospike nozzle wall shear stress with y position.
99
APPENDIX E: 40%Truncated aerospike nozzle Matlab thrust code
clc
close all
clear all
Yc= xlsread('YPContourNoBleed.xlsx','A:A');
Pc= xlsread('YPContourNoBleed.xlsx','B:B');
Yb= xlsread('YPBase.xlsx','A:A');
Pb= xlsread('YPBase.xlsx','B:B');
Po=4800000;
Patm=101325;
flux=7.89; %FROM CFD
Aty= pi*(0.05234828201^2-0.04909613294^2); %Projection of throat area on Y axis
Vx=460; %Average throat exit velocity
n = size(Yc)
k = size(Yb)
i = 1;
Fcenterbody=0;
Fthruster=0;
Fbase=0;
while 740 > i+1
dAy=pi.*(Yc(i+1).^2-Yc(i).^2);
dPavg=((Pc(i+1)+Pc(i))./2)-Patm;
i = i+1;
end
Fcenterbody=-Fcenterbody
i=1;
while 49 > i+1
dAy=pi.*(Yb(i+1).^2-Yb(i).^2);
dPavg=((Pb(i+1)+Pb(i))./2)-Patm;
Fbase=dPavg.*dAy+Fbase;
100
i = i+1;
end
Fbase=Fbase
Fviscous= -50.51 %From CFD
Total_Thrust= Fthruster + Fcenterbody + Fbase + Fviscous
SPecific_Impulse= Total_Thrust/(flux*9.81)
101
APPENDIX F: 20% Truncated Aerospike Nozzle
Figure F.1: 20% Truncated aerospike nozzle CAD model.
Figure F. 2: 20% Truncated aerospike plug CAD model.
Figure F. 3: 20% Truncated aerospike nozzle boundary condition definition.
102
Figure F.4: 20% Truncated aerospike nozzle element quality contours.
Figure F.5: 20% Truncated aerospike nozzle element quality chart.
Figure F.6: 20% Truncated aerospike nozzle skewness chart.
103
Figure F.7: 20% Truncated aerospike nozzle orthogonal quality chart.
Figure F.8: 20% Truncated aerospike nozzle fluent convergence graph.
Figure F 9: 20% Truncated aerospike nozzle velocity contours.
104
Figure F.10: 20% Truncated aerospike nozzle Mach lines.
Figure F.11: 20% Truncated aerospike nozzle streamlines.
105
Figure F.12: 20% Truncated aerospike nozzle temperature contours.
Figure F.13: 20% Truncated aerospike nozzle wall temperature with y axis.
106
Figure F.14: 20% Truncated aerospike nozzle wall adjacent static pressure with y
axis.
Figure F.15: 20% Truncated aerospike nozzle wall shear stress with y position.
107
APPENDIX G: 20% Truncated aerospike nozzle Matlab thrust code
clc
close all
clear all
Yc= xlsread('YPContour.xlsx','A:A');
Pc= xlsread('YPContour.xlsx','B:B');
Po=4800000;
Patm=101325;
Vx=460; %Average throat exit velocity in X Direction
n = size(Yc)
k = size(Yb)
i = 1;
Fcenterbody=0;
Fthruster=0;
Fbase=0;
while 401 > i+1
dAy=pi.*(Yc(i+1).^2-Yc(i).^2);
i = i+1;
end
i=1;
while 270 > i+1
dAy=pi.*(Yb(i+1).^2-Yb(i).^2);
108
i = i+1;
end
Fbase=-Fbase
109
APPENDIX H: 40% Truncated aerospike nozzle-blind central hole
Figure H.1: 40% Truncated aerospike nozzle-blind central hole-nozzle CAD model.
Figure H.2: 40% Truncated aerospike nozzle-blind central hole-plug CAD model.
Figure H.3: 40% Truncated aerospike nozzle-blind central hole-nozzle boundary

condition definition
110
.
Figure H.4: 40% Truncated aerospike nozzle-blind central hole-nozzle element quality
contours.
Figure H.5: 40% Truncated aerospike nozzle-blind central hole-nozzle element quality
chart.
Figure H.6: 40% Truncated aerospike nozzle-blind central hole-nozzle skewness chart.
111
Figure H.7: 40% Truncated aerospike nozzle-blind central hole-nozzle orthogonal
quality chart.
Figure H.8: 40% Truncated aerospike nozzle-blind central hole-nozzle convergence

graph.
112
Figure H.9: 40% Truncated aerospike nozzle-blind central hole-nozzle velocity
contours.
Figure H.10: 40% Truncated aerospike nozzle-blind central hole-nozzle Mach lines.
113
Figure H.11: 40% Truncated aerospike nozzle-blind central hole-nozzle streamlines.
Figure H.12: 40% Truncated aerospike nozzle-blind central hole-nozzle temperature

contours.
114
Figure H.13: 40% Truncated aerospike nozzle-blind central hole-nozzle wall
temperature with y axis.
Figure H.14: 40% Truncated aerospike nozzle-blind central hole-nozzle wall adjacent
static pressure with y axis.
115
Figure H.15: 40% Truncated aerospike nozzle-blind central hole-nozzle wall shear
stress with x position.
116
APPENDIX I: 40% Truncated aerospike nozzle-blind central hole-Matlab thrust
code
clc
close all
clear all
Po=4800000;
Patm=101325;
n = size(Yc)
k = size(Yb)
i = 1;
Fcenterbody=0;
Fthruster=0;
Fbase=0;
while 740 > i+1
dAy=pi.*(Yc(i+1).^2-Yc(i).^2);
i = i+1;
end
i=1;
while 49 > i+1
dAy=pi.*(Yb(i+1).^2-Yb(i).^2);
117
i = i+1;
end
Fbase=Fbase
118
APPENDIX J: 40%Truncated – 0.98%flux central straight bleed
Figure J.1: 40%Truncated – 0.98%flux central straight bleed velocity contours.
Figure J.2: 40%Truncated – 0.98%flux central straight bleed streamlines.
119
Figure J.3: 40%Truncated – 0.98%flux central straight bleed temperature contours.
Figure J.4: 40%Truncated – 0.98%flux central straight bleed

base exit static pressure with y axis.
120
Figure J.5: 40%Truncated – 0.98%flux central straight bleed base exit density with
y axis.
Figure J.6: 40%Truncated – 0.98%flux central straight bleed bleed exit velocity with
y axis.
121
APPENDIX K: 40%Truncated – 0.98%flux central straight bleed -Matlab thrust code
clc
close all
clear all
Po=4800000;
Patm=101325;
Flux_bleed = 0.0767;
V_Bleed_Exit = 285;
n = size(Yc)
k = size(Yb)
i = 1;
Fcenterbody=0;
Fthruster=0;
Fbase=0;
while 740 > i+1
dAy=pi.*(Yc(i+1).^2-Yc(i).^2);
i = i+1;
end
i=1;
while 10 > i+1
dAy=pi.*(Yb(i+1).^2-Yb(i).^2);
122
i = i+1;
end
Fbase=-Fbase
F_Bleed_Momentum= Flux_bleed * V_Bleed_Exit;
F_Bleed_viscous= -0.897 %From CFD
Total_Thrust= Fthruster + Fcenterbody + Fbase + Fviscous + F_Bleed_viscous +
F_Bleed_Momentum + F_Bleed_viscous
SPecific_Impulse= Total_Thrust/((flux+Flux_bleed)*9.81)
123
APPENDIX L: Hybrid aerospike conical nozzle-40%truncated – 2.9%flux central
bleed
Figure L.1: Hybrid aerospike conical nozzle-40%truncated – 2.9%flux central bleed-

nozzle CAD model.

plug CAD model.
124
element quality contours.

element quality chart.

skewness chart.
125
orthogonal quality chart.

convergence graph.

velocity contours.
126
Mach lines.
Figure L.10: Hybrid aerospike conical nozzle-40%truncated – 2.9%flux central

bleed-streamlines.
127
Figure L 11: Hybrid aerospike conical nozzle-40%truncated – 2.9%flux central
bleed-static pressure of base with y axis.

bleed-Mach number of full exit section of the whole nozzle with y axis.
128
bleed-flow velocity component in x direction of full exit section of the whole nozzle
with y axis.

bleed-wall shear stress with y position.
129
Temperature Contours.
130
APPENDIX M: Hybrid aerospike conical nozzle-40%truncated – 2.9%flux central
bleed-thrust Matlab code
clc
close all
clear all
Po=4800000;
Patm=101325;
Flux_bleed = 0.23;
V_Bleed_Exit = 1200;
n = size(Yc)
k = size(Yb)
i = 1;
Fcenterbody=0;
Fthruster=0;
Fbase=0;
while 740 > i+1
dAy=pi.*(Yc(i+1).^2-Yc(i).^2);
i = i+1;
end
i=1;
while 10 > i+1
131
dAy=pi.*(Yb(i+1).^2-Yb(i).^2);
i = i+1;
end
Fbase=-Fbase
F_Bleed_Momentum= Flux_bleed * V_Bleed_Exit
F_Bleed_viscous= -1.45 %From CFD
132
APPENDIX N: Hybrid Aerospike Conical Nozzle-40%Truncated – 5.9%Flux
Central Bleed
Figure N.1: Hybrid Aerospike Conical Nozzle-40%Truncated – 5.9%Flux Central

Bleed-nozzle CAD model.

Bleed-plug CAD nozzle.
133
Figure N.3: Hybrid aerospike conical nozzle-40%truncated – 5.9%flux central
bleed-element quality contours.

bleed-element quality chart.

bleed-skewness chart.
134
bleed-orthogonal quality chart.

bleed-convergence graph.
Figure N.8: Hybrid aerospike Conical Nozzle-40%Truncated – 5.9%Flux Central

Bleed-velocity contours.
135
Bleed-Mach lines.

Bleed-streamlines.
136
Figure N.11: Hybrid Aerospike conical nozzle-40%truncated – 5.9%flux central
bleed-temperature contours.

bleed-static pressure of base with y axis.
137
bleed-Mach number of full exit section of the whole nozzle with y axis.

bleed-flow velocity component in x direction of full exit section of the whole nozzle
with y axis.
138
bleed-wall shear stress with y position.
139
APPENDIX O: Hybrid Aerospike Conical Nozzle-40%Truncated – 5.9%Flux
Central Bleed-Thrust Matlab Code
clc
close all
clear all
Po=4800000;
Patm=101325;
Flux_bleed = 0.4655;
V_Bleed_Exit = 1575;
n = size(Yc)
k = size(Yb)
i = 1;
Fcenterbody=0;
Fthruster=0;
Fbase=0;
while 740 > i+1
dAy=pi.*(Yc(i+1).^2-Yc(i).^2);
i = i+1;
end
i=1;
while 10 > i+1
140
dAy=pi.*(Yb(i+1).^2-Yb(i).^2);
i = i+1;
end
Fbase=-Fbase
F_Bleed_Momentum= Flux_bleed * V_Bleed_Exit
F_Bleed_viscous= -9 %From CFD
141
APPENDIX P: 90% positioned secondary injection on 40% truncated aerospike
nozzle
Figure P.1: 90% positioned secondary injection on 40% truncated aerospike nozzle
CAD model.
mesh body partitioning.
142
detailed body partitioning.
detailed mesh elements1.
143
detailed mesh element2.
mesh quality contours.
144
detailed mesh quality contours1.
145

nozzle- element quality chart.

nozzle- skewness chart.
146
nozzle- orthogonal quality chart.

nozzle-convergence graph.
147
nozzle-wall Mach contours.

nozzle-Mach lines.
148
nozzle-velocity contours.

nozzle-detailed velocity contours.
149
nozzle-sectional velocity contours at secondary jet center.

nozzle-secondary jet streamlines.
150
nozzle-full streamlines.

nozzle-full streamlines-ISO.
151
nozzle-pressure contours.

nozzle-detailed pressure contours.
152
nozzle-sectional pressure contours at secondary jet center.

nozzle-wall temperature contours.
153
nozzle-temperature contours.

nozzle- sectional temperature contours at secondary jet center.
154
APPENDIX Q: 90% positioned secondary injection on 40% truncated aerospike
nozzle-Matlab code
clc
close all
clear all
Xc= xlsread('YPContour.xlsx','A:A');
Yc= xlsread('YPContour.xlsx','B:B');
Axc= xlsread('YPContour.xlsx','C:C');
Ayc= xlsread('YPContour.xlsx','D:D');
Pc= xlsread('YPContour.xlsx','E:E');
X_Jet= xlsread('YPJet.xlsx','A:A');
Y_Jet= xlsread('YPJet.xlsx','B:B');
Ay_Jet=xlsread('YPJet.xlsx','C:C');
P_Jet= xlsread('YPJet.xlsx','D:D');
Y_Base= xlsread('YPBase.xlsx','A:A');
Ax_Base= xlsread('YPBase.xlsx','B:B');
P_Base=xlsread('YPBase.xlsx','C:C');
Po=4800000;
Patm=101325;
Fthruster = -((flux*Vx)+(Po-Patm)*Aty)
Fviscous= 50.51 %From CFD
%Jet Nozzle Momentum

Jet_flux=0.0763; %From CFD
Vy_Jet_Avg=684; %From CFD
F_Jet_Momentum =(Jet_flux*-Vy_Jet_Avg)
Mz_Jet_Momentum=F_Jet_Momentum*0.05828
155
% % Jet Nozzle Pressure Calculation
F_Jet_Pressure=0;
i = 1;
while 1016 > i
F_Jet_Pressure=P_Jet(i)*Ay_Jet(i)+F_Jet_Pressure;
i = i+1;
end
F_Jet_Pressure= -F_Jet_Pressure*2
% Base Pressure & Base Moment

i=1;
Fx_Base=0;
Mz_Base_Fx=0;
Ry_Base=0;
while 6049 > i
Fx_Base=(P_Base(i)-101325)*Ax_Base(i)+Fx_Base;
Mz_Base_Fx=((P_Base(i)-101325)*Ax_Base(i))*(Y_Base(i))+Mz_Base_Fx; %No
Axis Correction Required
i = i+1;
end
Fx_Base=Fx_Base*2
Mz_Base_Fx=-Mz_Base_Fx*2
Ry_Base=-Mz_Base_Fx/Fx_Base % Y Position of the Base Resultant
% Contour Pressure Difference & Contour Moment calculation

i=1;
Fy_Contour=0;
Fx_Contour=0;
Mz_Contour_Fy=0;
Mz_Contour_Fx=0;
Ry_Contour=0;
Rx_Contour=0;
while 41251 > i
Fy_Contour=Pc(i)*Ayc(i)+Fy_Contour;
156
Fx_Contour=(Pc(i)-101325)*Axc(i)+Fx_Contour;
Mz_Contour_Fy=(Pc(i)*Ayc(i))*(Xc(i)-0.032)+Mz_Contour_Fy; %axis Correction to
start from Contour start line
Mz_Contour_Fx=((Pc(i)-101325)*Axc(i))*(Yc(i))+Mz_Contour_Fx; %No Axis
Correction Required
i = i+1;
end
Fy_Contour=Fy_Contour*2
Fx_Contour=Fx_Contour*2
Mz_Contour_Fy=Mz_Contour_Fy*2
Mz_Contour_Fx=-Mz_Contour_Fx*2
Ry_Contour=-Mz_Contour_Fx/Fx_Contour
Rx_Contour=Mz_Contour_Fy/Fy_Contour
%Total Values Calculations

Total_Thrust= Fx_Base+Fx_Contour
Total_Fy= F_Jet_Momentum +Fy_Contour
Total_Fx= Fx_Base+Fx_Contour
Total_Moment_Fy= Mz_Jet_Momentum+Mz_Contour_Fy;
Total_Moment_Fx= Mz_Base_Fx+Mz_Contour_Fx;
Xr=Total_Moment_Fy/Total_Fy
Xr_Percentage=(Xr/0.064756)*100
Yr=-Total_Moment_Fx/Total_Fx
%Amplified value Gained From Bow Shock wave
F_Jet_Amplification=Fy_Contour-F_Jet_Pressure %Contour Pressure Difference

without the jet pressure effect
F_Jet_Amplification_Factor=( Total_Fy /(Total_Fy- F_Jet_Amplification))
Total_Thrust= Fthruster + Fx_Contour + Fx_Base + Fviscous
SPecific_Impulse_Primary= -Total_Thrust/(flux*9.81)
SPecific_Impulse_Secondary= -Total_Fy/(Jet_flux*9.81)
157
APPENDIX R: 20% positioned secondary injection on 40% truncated aerospike
nozzle
velocity contours.
Mach lines.
158
detailed Mach lines.
pressure contours.
159
sectional pressure contours at secondary jet center.
160
CURRICULUM VITAE
Name Surname : Sherif FARRAG
Place and Date of Birth : Egypt, 18.10.1992
E-Mail : sherifezallo@gmail.com
EDUCATION:
 B.Sc.: 2017, Istanbul Technical University, Aerospace faculty, Department of

Aeronautics and Astronautics Engineering.
 M.Sc.: 2020, Istanbul Technical University, Aerospace faculty, Department of
Aeronautics and Astronautics Engineering
PROFESSIONAL EXPERIENCE AND REWARDS:
 ESRA (Experimental Sounding Rocket Association) competition, USA, 2015.

Rocket propulsion team leader.
Built the most powerful student-built solid rocket engine in Turkey that has been
marked safe and launched at the ESRA.
T.V interviews about the project:
URL-1 < https://www.youtube.com/watch?v=AZOpT3utO80&t=2s>
URL-2 < https://www.youtube.com/watch?v=TnrBtNr8-mo>
 URC (Universal Rover Challenge) world international competition, USA, 2014.

Ranked 9th.
 Iranian CanSat international Competition, USA, 2014. Ranked 7th.
 UNISEC-Egypt formal representative in Japan, 2014.
 Designing, manufacturing and implementation of Seven-hole Probe (B.Sc.
graduation project).
161

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ISTANBUL TECHNICAL UNIVERSITY  GRADUATE SCHOOL OF SCIENCE

ENGINEERING AND TECHNOLOGY

AEROSPIKE NOZZLE DESIGN AND ANALYSIS

Department of Aeronautical and Astronautical Engineering

Aeronautical and Astronautical Engineering Graduate Programme

AEROSPIKE NOZZLE DESIGN AND ANALYSIS

Department of Aeronautical and Astronautical Engineering

Aeronautical and Astronautical Engineering Graduate Programme

Thesis Advisor: Prof. Dr. Fırat Oğuz EDİS

AEROSPİKE NOZUL TASARIMI VE ANALİZİ

YÜKSEK LİSANS TEZİ

Uçak ve Uzay Mühendisliği Anabilim Dalı

Uçak ve Uzay Mühendisliği Yüksek Lisans Programı

Tez Danışmanı: Prof. Dr. Fırat Oğuz EDİS

Thesis Advisor: Prof. Dr. Fırat Oğuz Edis ..............................

Jury Members: Doç. Dr. Ayşe Gül Güngör .............................

Prof. Dr. Metin Muradoğlu ..............................

Date of Submission : 14 June 2020

This thesis is considered to be as a development on the experience which I self-built

June 2020 Sherif FARRAG

CAD : Computer Aided Drafting

CFD : Computational Fluid Dynamics

ITU : Istanbul Technical University

MOC : Method of Characteristics

“Base” or b : Aerospike Nozzle Front Base Section (if there is truncation)

thruster : Case Without Nozzle Centerbody

1.1 Nozzle Definition

Conical nozzle is similar to all nozzle types. It has convergence-divergence sections.

1.2.2 Bell nozzle

1.2.3 Aerospike nozzle

2.1 Working Principle

Figure 2.4 : Exhaust Flow along a Truncated Aerospike Nozzle [2].

In an aerospike nozzle the flow compensates automatically to the ambient pressure

2.2 Governing Equation

Figure 2. 7 : Sketch of full-length aerospike nozzle contour according to Wang &

This method is an approximated method and does not show a great

B. The B-Spline Method [7] [8]

1, 𝑢𝑖 < 𝑢 < 𝑢𝑖+1

C. Rao Method [9]

F. Angelino approximate method [12]

Figure 2.9 : Two-dimensional plug nozzle [12].

Figure 2.11 : Annular plug nozzle [12].

Assumptions and boundaries:

Ae = π(𝑟𝑒2 − 𝑟𝑏2 ) (2.8)

2.4 Thrust Calculations

Figure 2. 12 : Conical nozzle flow sketch [14].

∑ 𝐹𝑥 = 𝑇 + (𝑝𝑎 − 𝑝𝑒 )𝐴𝑒 ∫𝐶𝑆 𝜌(𝑣⃗. 𝑛⃗⃗)𝑣𝑥 𝑑𝐴 (2.13)

𝑇𝑖𝑠𝑒𝑛𝑡𝑟,1−𝑑 = 𝑚̇𝑣𝑒 + (𝑝𝑒 − 𝑝𝑎 )𝐴𝑒 (2.14)

Real nozzle thrust due to convergent angle loss:

2.4.2 Aerospike nozzle [15] [16] [17]

T = Fthruster + FCenterbody + Fbase (2.17)

Fthruster = (ṁvexit + (pexit-p0)Aexit)cos θ (2.18)

Fthruster = thrust force acting on the thrust

Fcenterbody = ∫ Acenterbody (pcenterbody − p∞ )𝑑A (2.19)

Fbase = (pbase – p∞ ) Abase (2.20)

Fbase = thrust force acting on the base

In this section Aerospike nozzle is analyzed, studied and compared according to

1- Full Spike Nozzle

3.1 Full Spike Nozzle

3.1.1 Cad model